U.S. patent application number 10/113998 was filed with the patent office on 2002-10-03 for metal vanadium oxide particles.
This patent application is currently assigned to NanoGram Corporation. Invention is credited to Bi, Xiangxin, Buckley, James P., Fortunak, Yu K., Kumar, Sujeet, Reitz, Hariklia Dris.
Application Number | 20020142218 10/113998 |
Document ID | / |
Family ID | 23207199 |
Filed Date | 2002-10-03 |
United States Patent
Application |
20020142218 |
Kind Code |
A1 |
Reitz, Hariklia Dris ; et
al. |
October 3, 2002 |
Metal vanadium oxide particles
Abstract
Laser pyrolysis can be used to produce directly metal vanadium
oxide composite nanoparticles. To perform the pyrolysis a reactant
stream is formed including a vanadium precursor and a second metal
precursor. The pyrolysis is driven by energy absorbed from a light
beam- Metal vanadium oxide nanoparticles can be incorporated into a
cathode of a lithium based battery to obtain increased energy
densities. Implantable defibrillators can be constructed with
lithium based batteries having increased energy densities.
Inventors: |
Reitz, Hariklia Dris; (Santa
Clara, CA) ; Buckley, James P.; (San Jose, CA)
; Kumar, Sujeet; (Fremont, CA) ; Fortunak, Yu
K.; (Fremont, CA) ; Bi, Xiangxin; (San Ramon,
CA) |
Correspondence
Address: |
Patterson, Thuente, Skaar & Christensen, P.A.
4800 IDS Center
80 South 8th Street
Minneapolis
MN
55402-2100
US
|
Assignee: |
NanoGram Corporation
|
Family ID: |
23207199 |
Appl. No.: |
10/113998 |
Filed: |
April 1, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10113998 |
Apr 1, 2002 |
|
|
|
09311506 |
May 13, 1999 |
|
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|
6391494 |
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Current U.S.
Class: |
429/219 ;
204/157.51; 423/594.8 |
Current CPC
Class: |
H01M 4/54 20130101; Y02E
60/10 20130101; H01M 10/052 20130101; H01M 4/131 20130101; H01M
4/1391 20130101 |
Class at
Publication: |
429/219 ;
423/593; 204/157.51 |
International
Class: |
C01G 031/02; C01F
001/00; H01M 004/54 |
Claims
What is claimed is:
1. A method for producing metal vanadium oxide particles comprising
reacting a reactant stream comprising a vanadium precursor, and a
second metal precursor in a reaction chamber, where the reaction is
driven by energy absorbed from an electromagnetic field.
2. The method of claim 1 wherein the reactant stream further
comprises a reactant that is an oxygen source.
3. The method of claim 1 wherein the reactant stream further
comprises a radiation absorbing compound.
4. The method of claim 1 wherein the vanadium precursor within the
reactant stream is in the form of an aerosol.
5. The method of claim 1 wherein the second metal precursor within
the reactant stream is in the form of an aerosol.
6. The method of claim 1 wherein both the vanadium precursor and
the second metal precursor within the reactant stream are in the
form of an aerosol.
7. The method of claim 1 wherein the metal vanadium oxide particles
have an average diameter from about 5 nm to about 100 nm.
8. The method of claim 1 wherein the metal vanadium oxide particles
comprise silver vanadium oxide, Ag.sub.xV.sub.2O.sub.y,
0.3.ltoreq.x.ltoreq.2.0, 4.5.ltoreq.y.ltoreq.6.0.
9. The method of claim 1 wherein the metal vanadium oxide particles
comprise Ag.sub.2V.sub.4O.sub.11.
10. The method of claim 1 wherein effectively no metal vanadium
oxide particles have a diameter greater than about four times the
average diameter of the collection of particles.
11. The method of claim 1 wherein the metal vanadium oxide
particles have a distribution of particle sizes such that at least
about 95 percent of the particles have a diameter greater than
about 40 percent of the average diameter and less than about 160
percent of the average diameter.
12. The method of claim 1 wherein the second metal precursor
comprises silver cations.
13. The method of claim 1 wherein the vanadium precursor comprises
vanadium cations.
14. A battery comprising a cathode having active particles
comprising silver vanadium oxide and a binder, the positive
electrode exhibiting an energy density of greater than about 340
milliampere hours per gram of active particles when discharged to
about 1.0V.
15. The battery of claim 14 wherein the active particles have an
average diameter from about 5 nm to about 100 nm.
16. The battery of claim 14 wherein the silver vanadium oxide
comprises silver vanadium oxide, Ag.sub.xV.sub.2O.sub.y,
0.3.ltoreq.x.ltoreq.2.0, 4.5.ltoreq.y.ltoreq.6.0.
17. The battery of claim 16 wherein the silver vanadium oxide
comprises Ag.sub.2V.sub.4O.sub.11.
18. The battery of claim 14 wherein the cathode further comprises
supplementary, electrically conductive particles.
19. The battery of claim 14 wherein the cathode exhibits an energy
density of greater than about 350 milliampere hours per gram of
active particles.
20. An implantable defibrillator comprising a lithium based battery
having a cathode comprising silver vanadium oxide with an energy
density upon discharge to about 1.0V of greater than about 340
milliampere hours per gram of cathode active material.
21. A battery comprising a cathode having active particles
comprising metal vanadium oxide and a binder, the positive
electrode exhibiting an energy density of greater than about 400
milliampere hours per gram of active particles when discharged to
about 1.0V.
22. A method of producing a composite of elemental metal
nanoparticles and vanadium oxide nanoparticles, the method
comprising reacting a reactant stream comprising a vanadium
precursor, and a second metal precursor in a reaction chamber,
where the reaction is driven by energy absorbed from an
electromagnetic field.
23. A method for producing metal vanadium oxide particles
comprising reacting a reactant stream comprising a vanadium
precursor, and a second metal precursor in a reaction chamber,
where the reaction is driven by energy absorbed from a combustion
flame.
24. A method of producing particles comprising a an elemental metal
selected from the group consisting copper, silver and gold, the
method comprising reacting a molecular stream in a reaction
chamber, the molecular stream comprising a metal precursor and a
radiation absorber, where the reaction is driven by electromagnetic
radiation.
Description
FIELD OF THE INVENTION
[0001] The invention relates to methods for producing particles of
metal vanadium oxide powders through laser pyrolysis. In
particular, the invention relates to the use of laser pyrolysis for
the production of nanoscale metal vanadium oxide particles. The
invention further relates to batteries with improved performance
that incorporate nanoscale metal vanadium oxides particles, such as
silver vanadium oxide particles.
BACKGROUND OF THE INVENTION
[0002] Lithium based batteries have become commercially successful
due to their relatively high energy density. Suitable positive
electrode materials for lithium based batteries include materials
that can intercalate lithium atoms into their lattice. The negative
electrode can be lithium metal lithium alloys or compounds that can
reversibly intercalate lithium atoms into their lattice. Batteries
formed from lithium metal or lithium alloy negative electrodes are
referred to as lithium batteries while batteries formed with an
anode (negative electrode) active material that can intercalate
lithium ions are referred to as lithium ion batteries.
[0003] In order to produce improved batteries, various materials
have been examined for use as cathode (positive electrode) active
materials for lithium based batteries. A variety of materials,
generally chalcogenides, are useful in lithium based batteries. For
example, vanadium oxides in certain oxidation states are effective
materials for the production of positive electrodes for lithium
based batteries. Also, metal vanadium oxide compositions have been
identified as having high energy densities and high power
densities, when used in positive electrodes for lithium based
batteries. Silver vanadium oxide has a particularly high energy
density and high power densities, when used in lithium based
batteries. Silver vanadium oxide batteries have found particular
use in the production of implantable cardiac defibrillators where
the battery must be able to recharge a capacitor to deliver large
pulses of energy in rapid succession, within ten seconds or
less.
SUMMARY OF THE INVENTION
[0004] In a first aspect, the invention pertains to a method for
producing metal vanadium oxide particles comprising reacting a
reactant stream comprising a vanadium precursor, and a second metal
precursor in a reaction chamber. The reaction is driven by energy
absorbed from an electromagnetic field.
[0005] In another aspect, the invention pertains to a battery
comprising a cathode having active particles comprising silver
vanadium oxide and a binder. The positive electrode exhibits an
energy density of greater than about 340 milliampere hours per gram
of active particles when discharged to about 1.0 V.
[0006] In addition, the invention pertains to a battery comprising
a cathode having active particles comprising metal vanadium oxide
and a binder, the positive electrode exhibiting an energy density
of greater than about 400 milliampere hours per gram of active
particles when discharged to about 1.0V.
[0007] In a further aspect, the invention pertains to an
implantable defibrillator comprising a battery having a cathode
comprising silver vanadium oxide with an energy density upon
discharge to about 1.0V of greater than about 340 milliampere hours
per gram of cathode active material.
[0008] Moreover, the invention pertains to a method of producing a
composite of elemental metal nanoparticles and vanadium oxide
nanoparticles, the method comprising reacting a reactant stream
comprising a vanadium precursor, and a second metal precursor in a
reaction chamber, where the reaction is driven by energy absorbed
from an electromagnetic field.
[0009] In another aspect, the invention pertains to a method for
producing metal vanadium oxide particles comprising reacting a
reactant stream comprising a vanadium precursor, and a second metal
precursor in a reaction chamber, where the reaction is driven by
energy absorbed from a combustion flame.
[0010] In an additional aspect, the invention pertains to a
collection of particles comprising elemental metal selected from
the group consisting of copper, silver, and gold, the particles,
the collection of particles having an average particle size less
than about 500 nm, and effectively no particles have a diameter
greater than about four times the average diameter.
[0011] In addition, the invention pertains to a method of producing
particles comprising a an elemental metal selected from the group
consisting copper, silver and gold, the method comprising reacting
a molecular stream in a reaction chamber, the molecular stream
comprising a metal precursor and a radiation absorber, where the
reaction is driven by electromagnetic radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic, sectional view of an embodiment of a
laser pyrolysis apparatus, where the cross section is taken through
the middle of the laser radiation path. The upper insert is a
bottom-view of the collection nozzle, and the lower insert is a top
view of the delivery nozzle.
[0013] FIG. 2 is a schematic view of a reactant delivery apparatus
for the delivery of vapor reactants to the laser pyrolysis
apparatus of FIG. 1.
[0014] FIG. 3A is schematic, side view of a reactant delivery
apparatus for the delivery of an aerosol reactant to the laser
pyrolysis apparatus of FIG. 1.
[0015] FIG. 3B is a schematic, side view of an alternative
embodiment of a reactant delivery apparatus for the delivery of an
aerosol reactant to the laser pyrolysis apparatus of FIG. 1.
[0016] FIG. 4 is a schematic, perspective view of an elongated
reaction chamber for the performance of laser pyrolysis, where
components of the reaction chamber are shown as transparent to
reveal internal structure.
[0017] FIG. 5 is a sectional view of the reaction chamber of FIG. 4
taken along line 5-5.
[0018] FIG. 6 is a schematic, sectional view of an apparatus for
heat treating nanoparticles, in which the section is taken through
the center of the apparatus.
[0019] FIG. 7 is a schematic, sectional view of an oven for
reacting nanoparticles under heat, in which the section is taken
through the middle of the oven.
[0020] FIG. 8 is a schematic, perspective view of an embodiment of
a battery of the invention.
[0021] FIG. 9 is an x-ray diffractogram of crystalline VO.sub.2
nanoparticles.
[0022] FIG. 10 is an x-ray diffractogram of crystalline
V.sub.2O.sub.5 nanoparticles produced by heat treating
nanoparticles of crystalline VO.sub.2.
[0023] FIG. 11 is a transmission electron microscope view of
crystalline V.sub.2O.sub.5 nanoparticles.
[0024] FIG. 12 is a plot depicting the distribution of particle
sizes for the crystalline V.sub.2O.sub.5 nanoparticles depicted in
FIG. 11.
[0025] FIG. 13 is a plot of four x-ray diffractograms of silver
vanadium oxide produced by heat treating nanocrystalline
V.sub.2O.sub.5 with silver nitrate in an oxygen atmosphere, where
each diffractogram was produced with materials formed under
different conditions.
[0026] FIG. 14 is a plot of four x-ray diffractograms of silver
vanadium oxide produced by heat treating nanocrystalline
V.sub.2O.sub.5 with silver nitrate in an argon atmosphere, where
each diffractogram was produced with materials formed under
different conditions.
[0027] FIG. 15 is a transmission electron microscope view of silver
vanadium oxide nanoparticles.
[0028] FIG. 16 is a transmission electron microscope view of the
V.sub.2O.sub.5 nanoparticle samples used to produce the silver
vanadium oxide particles shown in FIG. 15.
[0029] FIG. 17 is an x-ray diffractogram of silver vanadium oxide
produced by heat treating a mixture of nanocrystalline VO.sub.2 and
silver nitrate powder in an oxygen atmosphere.
[0030] FIG. 18 is a plot of differential scanning calorimetry
measurements obtained with samples with an x-ray diffractogram as
shown in FIG. 17.
[0031] FIG. 19 is a plot of an x-ray diffractogram of mixed phase
silver--vanadium oxide materials produced directly by laser
pyrolysis synthesis.
[0032] FIG. 20 is a transmission electron micrograph of
silver--vanadium oxide materials produced directly by laser
pyrolysis synthesis, which produce an x-ray diffractogram as shown
in FIG. 19.
[0033] FIG. 21 is an x-ray diffractogram of silver vanadium oxide
particles following a heat treatment in an oxygen atmosphere of
nanoscale silver--vanadium oxide materials as synthesized by laser
pyrolysis.
[0034] FIG. 22 is a transmission electron micrograph of silver
vanadium oxide particles produced by heat treating nanoscale
silver--vanadium oxide materials.
[0035] FIG. 23 is a plot of two x-ray diffractograms of mixed phase
materials including silver vanadium oxide nanoparticles produced
directly by laser pyrolysis, where each plot is produced with
materials produced under slightly different conditions.
[0036] FIG. 24A is a transmission electron micrograph of the
materials from the sample corresponding to the upper diffractogram
in FIG. 23.
[0037] FIG. 24B is a transmission electron micrograph of the
materials from the sample corresponding to the lower diffractogram
in FIG. 23.
[0038] FIG. 25 is a plot of five x-ray diffractograms of mixed
phase materials including silver vanadium oxide nanoparticles
produced directly by laser pyrolysis, where each plot is produced
with materials produced with a different silver to vanadium
ratio.
[0039] FIG. 26 is an x-ray diffractogram of elemental silver
nanoparticles produced by laser pyrolysis under the conditions
specified in the first column of Table 5.
[0040] FIG. 27 is an x-ray diffractogram of elemental silver
nanoparticles produced by laser pyrolysis under the conditions
specified in the second column of Table 5.
[0041] FIG. 28 is a transmission electron micrograph of the
materials from the sample corresponding to the diffractogram in
FIG. 26.
[0042] FIG. 29 is a plot of voltage as a function of time for a
lithium battery produced using silver vanadium oxide nanoparticles
produced in a heat processing step described in Example 4.
[0043] FIG. 30 is a plot of voltage as a function of capacity
corresponding to the plot of voltage as a function of time shown in
FIG. 29.
[0044] FIG. 31 is a plot of voltage as a function of time for a
lithium battery produced using mixed phase silver vanadium oxide
nanoparticles as produced directly by laser pyrolysis, as described
in Example 5.
[0045] FIG. 32 is a plot of voltage as a function of capacity
corresponding to the plot of voltage as a function of time shown in
FIG. 31.
[0046] FIG. 33 is a plot of voltage as a function of time for a
lithium battery produced using silver vanadium oxide nanoparticles
following heat treatment, as described in Example 6.
[0047] FIG. 34 is a plot of voltage as a function of capacity
corresponding to the plot of voltage as a function of time shown in
FIG. 33.
[0048] FIG. 35 is a plot of voltage as a function of time for a
lithium battery produced using mixed phase silver vanadium oxide
nanoparticles, as described in Example 7.
[0049] FIG. 36 is a plot of voltage as a function of capacity
corresponding to the plot of voltage as a function of time shown in
FIG. 35.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] Nanoscale metal vanadium oxide particles can be produced
either directly through laser pyrolysis or by the application of
laser pyrolysis to synthesize nanoscale vanadium oxide particles,
which are subjected subsequently to thermal/heat processing to form
the metal vanadium oxide nanoparticles. Thus, metal vanadium oxides
can be produced directly by laser pyrolysis, where the laser
pyrolysis reactants include precursors of vanadium as well as
precursors of a second metal. In addition, vanadium oxide
nanoparticles can be used to form metal vanadium oxide
nanoparticles, such as silver vanadium oxide nanoparticles, without
losing the nanoscale size of the particles. Nanoscale metal
vanadium oxide particles can be used to form batteries with
improved performance.
[0051] Vanadium oxide nanoparticles with various stoichiometries
and crystal structures can be produced by laser pyrolysis alone or
with additional processing. These various forms of vanadium oxide
nanoparticles can be used as starting materials for the formation
of metal vanadium oxide nanoparticles. The multiple metal
nanoparticles are formed by mixing the vanadium oxide nanoparticles
with a compound of the metal to be introduced into the vanadium
oxide to form a material with both metals in the lattice. By using
appropriately selected processing conditions, the particles
incorporating both metals can be formed without losing the
nanoscale character of the initial vanadium oxide
nanoparticles.
[0052] Preferred collections of metal vanadium oxide particles have
an average diameter less than a micron and a very narrow
distribution of particle diameters. In particular, the distribution
of particle diameters preferably does not have a tail. In other
words, there are effectively no particles with a diameter an order
of magnitude greater than the average diameter such that the
particle size distribution rapidly drops to zero.
[0053] To generate vanadium oxide nanoparticle starting materials
for further processing into metal vanadium oxides, laser pyrolysis
is used either alone or in combination with additional processing.
Specifically, laser pyrolysis has been found to be an excellent
process for efficiently producing vanadium oxide nanoparticles with
a narrow distribution of average particle diameters. In addition,
nanoscale vanadium oxide particles produced by laser pyrolysis can
be subjected to heating under mild conditions in an oxygen
environment or an inert environment to alter the crystal properties
and/or the stoichiometry of the vanadium oxide particles without
destroying the nanoparticle size. Thus, a variety of different
types of vanadium oxide based nanoparticles can be produced.
[0054] A basic feature of successful application of laser pyrolysis
for the production of vanadium oxide nanoparticles is production of
a reactant stream containing a vanadium precursor, a radiation
absorber and an oxygen source. The reactant stream is pyrolyzed by
an intense light beam, such as a laser beam. The laser pyrolysis
provides for formation of phases of materials that are difficult to
form under thermodynamic equilibrium conditions. As the reactant
stream leaves the light beam, the vanadium oxide particles are
rapidly quenched.
[0055] Starting with nanoscale vanadium oxide particles, metal
vanadium oxide particles can be formed by a thermal process. A
second metal precursor comprises a non-vanadium transition metal.
Preferred second metal precursors include compositions with copper,
silver or gold. The second metal precursor compound is mixed with a
collection of vanadium oxide nanoparticles and heated to form the
particles incorporating both metals. Under suitably mild
conditions, the heat processing is effective to produce the
particles while not destroying the nanoscale of the initial
vanadium oxide particles.
[0056] As noted above, a basic feature of the successful
application of laser pyrolysis for the direct production of metal
vanadium oxide nanoparticles is the production of a reactant stream
containing a vanadium precursor, a precursor for a second metal, a
radiation absorber and an oxygen source. The reactant stream is
pyrolyzed by an intense light beam, such as a laser beam or other
intense light source. As the reactant stream leaves the light beam,
the metal vanadium particles are rapidly quenched to yield metal
vanadium oxide nanoparticles with a highly uniform size
distribution.
[0057] As noted above, lithium atoms and/or ions can intercalate
into various forms of vanadium oxide and metal vanadium oxide
particles. To form a positive electrode, which acts as a cathode
upon discharge of the cell, the metal vanadium oxide nanoparticles
can be incorporated into a electrode with a binder such as a
polymer. The electrode preferably incorporates additional
electrically conductive particles held by a binder along with the
metal vanadium oxide particles. The electrode can be used as a
positive electrode in a lithium battery or a lithium ion battery.
Lithium based batteries formed with cathodes including nanoscale
metal vanadium oxides have energy densities higher than theoretical
maximum values estimated for corresponding bulk metal vanadium
oxides. In particular, metal vanadium oxides, specifically silver
vanadium oxides, have been produced with an energy density greater
than about 340 milliampere hours per gram have been produced.
Preferred metal vanadium oxide particles exhibit an energy density
greater than about 350 milliampere hours per gram, and preferably
greater than about 360 milliampere hours per gram, and more
preferably from about 370 milliampere hours per gram to about 405
milliampere hours per gram.
[0058] While the primary focus is on the use of laser pyrolysis for
the production of metal vanadium oxide nanoparticles or precursors
of metal vanadium oxide nanoparticles, the approaches described
herein for aerosol precursor delivery can be adapted for other
synthesis approaches. In particular, the precursors can be used in
a flame pyrolysis method. The precursor delivery approaches can be
adapted for a variety of flame pyrolysis approaches. In one
preferred approach, the reactant stream is directed into a
hydrogen-oxygen flame. The flame supplies the energy to drive the
pyrolysis. Such a flame pyrolysis approach should produce similar
materials as the laser pyrolysis techniques herein, except that
flame pyrolysis approaches generally do not produce a narrow
particle size distribution.
[0059] While the focus herein is the production of ternary
compounds involving two metal constituents, approaches have also
been discovered to produce nanoparticles of group IB elemental
metals with extremely high uniformity. In particular, an example of
the production of elemental silver nanoparticles is provided below.
Copper and gold, the other group IB elements, have similar
chemistry, so that copper and gold nanoparticles can be produced by
similar approaches.
[0060] A. Laser Pyrolysis For Nanoparticle Production
[0061] Laser pyrolysis has been discovered to be a valuable tool
for the production of nanoscale vanadium oxide particles. In
addition, the particles produced by laser pyrolysis are a
convenient material for further processing to expand the pathways
for the production of desirable vanadium oxide particles. Thus,
using laser pyrolysis alone or in combination with additional
processes, a wide variety of vanadium oxide particles can be
produced. Furthermore, laser pyrolysis has been discovered to be a
successful approach for the direct production of metal vanadium
oxide particles.
[0062] The reaction conditions determine the qualities of the
particles produced by laser pyrolysis. The reaction conditions for
laser pyrolysis can be controlled relatively precisely in order to
produce particles with desired properties. The appropriate reaction
conditions to produce a certain type of particles generally depend
on the design of the particular apparatus. Specific conditions used
to produce vanadium oxide particles in a particular apparatus are
described below in the Examples. Additional information on the
production of vanadium oxide nanoparticles by laser pyrolysis is
provided in copending and commonly assigned U.S. patent application
Ser. No. 08/897,778 to Bi et al., entitled "Vanadium Oxide
Nanoparticles," incorporated herein by reference. In addition,
specific conditions for the direct production of silver vanadium
oxide particles by laser pyrolysis in a particular apparatus also
are described below in the Examples. Furthermore, some general
observations on the relationship between reaction conditions and
the resulting particles can be made.
[0063] Increasing the laser power results in increased reaction
temperatures in the reaction region as well as a faster quenching
rate. A rapid quenching rate tends to favor production of high
energy phases, which may not be obtained with processes near
thermal equilibrium. Similarly, increasing the chamber pressure
also tends to favor the production of higher energy structures.
Also, increasing the concentration of the reactant serving as the
oxygen source in the reactant stream favors the production of
particles with increased amounts of oxygen.
[0064] Reactant flow rate and velocity of the reactant gas stream
are inversely related to particle size so that increasing the
reactant gas flow rate or velocity tends to result in smaller
particle size. Also, the growth dynamics of the particles have a
significant influence on the size of the resulting particles. In
other words, different forms of a product compound have a tendency
to form different size particles from other phases under relatively
similar conditions. Laser power also influences particle size with
increased laser power favoring larger particle formation for lower
melting materials and smaller particle formation for higher melting
materials.
[0065] Laser pyrolysis has been performed generally with gas phase
reactants. The use of exclusively gas phase reactants is somewhat
limiting with respect to the types of precursor compounds that can
be used. Thus, techniques have been developed to introduce aerosols
containing reactant precursors into laser pyrolysis chambers. The
aerosol atomizers can be broadly classified as ultrasonic
atomizers, which use an ultrasonic transducer to form the aerosol,
or as mechanical atomizers, which use energy from one or more
flowing fluids (liquids, gases, or supercritical fluids) themselves
to form the aerosol. Improved aerosol delivery apparatuses for
reactant systems, including laser pyrolysis apparatuses, are
described further in copending and commonly assigned U.S. patent
application Ser. No. 09/188,670 to Gardner et al., entitled
"Reactant Delivery Apparatuses," incorporated herein by
reference.
[0066] Using aerosol delivery apparatuses, solid precursor
compounds can be delivered by dissolving the compounds in a
solvent. Alternatively, powdered precursor compounds can be
dispersed in a liquid.backslash.solvent for aerosol delivery.
Liquid precursor compounds can be delivered as an aerosol from a
neat liquid, a liquid/gas mixture, liquid mixtures or a liquid
solution, if desired. Aerosol reactants can be used to obtain
significant reactant throughput. The solvent, if any, can be
selected to achieve desired properties of the solution Suitable
solvents include water, methanol, ethanol and other organic
solvents The solvent should have a desired level of purity such
that the resulting particles have a desired purity level.
[0067] If the aerosol precursors are formed with a solvent present,
the solvent is rapidly evaporated by the laser beam in the reaction
chamber such that a gas phase reaction can take place. Thus, the
fundamental features of the laser pyrolysis reaction are unchanged.
However, the reaction conditions are affected by the presence of
the aerosol. Suitable conditions for the formation of manganese
oxide nanoparticles by laser pyrolysis with aerosol precursors are
described in copending and commonly assigned U.S. patent
application Ser. No. 09/188,770, filed on Nov. 9, 1998, entitled
"Metal Oxide Particles," incorporated herein by reference. Suitable
conditions for the production of silver vanadium oxide particles by
laser pyrolysis with aerosol precursors are described in the
Examples below.
[0068] Suitable vanadium precursors for aerosol production include,
for example, vanadium trichloride (VCl.sub.3), vanadyl trichloride
(VOCl.sub.3), vanadyl sulfate hydrate (VOSO.sub.4.H.sub.2O),
ammonium vanadate (NH.sub.4VO.sub.3), vanadium oxide compounds
(e.g., V.sub.2O.sub.5 and V.sub.2O.sub.3, which are soluble in
aqueous nitric acid), and vanadyl dichloride (VOCl.sub.2), which is
soluble in absolute alcohol. Suitable silver precursors include,
for example, silver sulfate (Ag.sub.2SO.sub.4), silver carbonate
(Ag.sub.2CO.sub.3), silver nitrate (AgNO.sub.3), silver chlorate
(AgClO.sub.3) and silver perchlorate (AgClO.sub.4). Suitable copper
precursors include, for example, cupric nitrate
(Cu(NO.sub.3).sub.2), cupric chloride (CuCl.sub.2), cuprous
chloride (CuCl) and cupric sulfate (CuSO.sub.4) . Suitable gold
precursors include, for example, gold trichloride (AuCl.sub.3) and
gold powder.
[0069] The compounds are dissolved in a solution preferably with a
concentration greater than about 0.1 molar. Generally, the greater
the concentration of precursor in the solution the greater the
throughput of reactant through the reaction chamber. As the
concentration increases, however, the solution can become more
viscous such that the aerosol has droplets with larger sizes than
desired. Thus, selection of solution concentration can involve a
balance of factors in the selection of a preferred solution
concentration.
[0070] Appropriate vanadium precursor compounds for vapor delivery
generally include vanadium compounds with reasonable vapor
pressures, i.e., vapor pressures sufficient to get desired amounts
of precursor vapor in the reactant stream. The vessel holding a
solid or liquid vanadium precursor compound can be heated to
increase the vapor pressure of the vanadium precursor, if desired.
Suitable vanadium precursors include, for example, VCl.sub.4,
VOCl.sub.2, V(CO).sub.6 and VOCl.sub.3. The chlorine in these
representative precursor compounds can be replaced with other
halogens, e.g., Br, I and F.
[0071] For the production of metal vanadium oxide particles,
suitable metal precursors have sufficient vapor pressure to obtain
desired amounts of metal precursor vapor in the reactant stream.
Suitable copper precursors for vapor delivery include, for example,
cupric chloride (CuCl.sub.2) . Suitable silver precursors for vapor
delivery include, for example, silver chloride (AgCl).
Alternatively, one of the vanadium precursor and metal precursor
can be delivered as an aerosol while the other is delivered as a
vapor. In particular, the metal precursor, such as a silver
precursor, can be delivered as an aerosol while the vanadium
precursor is delivered as a vapor.
[0072] For the production of mixed metal oxides with two or more
metals, the relative amounts of the metals in the reactant stream
can be altered to vary the relative amounts of metal in the
resulting compositions. The phase diagram for mixed metal oxides is
necessarily more complex than corresponding phase diagrams for
metal oxides. Thus, the addition of a relatively larger amount of
one metal relative to the other can result in production of phases
with increased amounts of that metal, either as a major phase or as
a larger relative quantity in a mixed phase product.
[0073] Therefore, the stoichiometry of the product particles can be
altered by varying the relative amounts of metals within the
solution or dispersion for aerosol delivery. Similar results can be
obtained by delivering the metal precursors as two or more separate
aerosols, where the relative amounts of metal precursors can be
varied by changing the concentrations of the metals in the liquid
and/or by the relative amounts of aerosol. Furthermore, one or more
of the metal precursors can be delivered in a vapor state, and the
relative amounts of metal can be appropriately adjusted to obtain a
desired product.
[0074] Preferred reactants serving as oxygen source include, for
example, O.sub.2, CO, CO.sub.2, O.sub.3 and mixtures thereof. The
reactant compound serving as the oxygen source should not react
significantly with the vanadium precursor or other metal precursor
prior to entering the reaction zone since this generally would
result in the formation of large particles.
[0075] Laser pyrolysis can be performed with a variety of optical
light frequencies. Preferred light sources include lasers,
especially lasers that operate in the infrared portion of the
electromagnetic spectrum. CO.sub.2 lasers are particularly
preferred sources of light. Infrared absorbers for inclusion in the
molecular stream include, for example, C.sub.2H.sub.4, isopropyl
alcohol (CH.sub.3CHOHCH.sub.3), NH.sub.3, SF.sub.6, SiH.sub.4 and
O.sub.3. O.sub.3 can act as both an infrared absorber and as an
oxygen source. Alternatively, a solvent, such as isopropyl alcohol,
in a liquid delivered by aerosol can absorb light from the light
beam. The radiation absorber, such as the infrared absorber,
absorbs energy from the radiation beam and distributes the energy
to the other reactants to drive the pyrolysis.
[0076] Preferably, the energy absorbed from the radiation beam
increases the temperature at a tremendous rate, many times the rate
that energy generally would be produced even by strongly exothermic
reactions under controlled condition. While the process generally
involves nonequilibrium conditions, the temperature can be
described approximately based on the heat in the absorbing region.
The laser pyrolysis process is qualitatively different from the
process in a combustion reactor where an energy source initiates a
reaction, but the reaction is driven by energy given off by an
exothermic reaction.
[0077] An inert shielding gas can be used to reduce the amount of
reactant and product molecules contacting the reactant chamber
components. Appropriate shielding gases include, for example, Ar,
He and N.sub.2. Inert gas can also be mixed with the reactant
stream to moderate the reaction.
[0078] An appropriate laser pyrolysis apparatus generally includes
a reaction chamber isolated from the ambient environment. A
reactant inlet connected to a reactant supply system produces a
reactant stream through the reaction chamber. A light beam path
intersects the reactant stream at a reaction zone. The is
reactant/product stream continues after the reaction zone to an
outlet, where the reactant/product stream exits the reaction
chamber and passes into a collection system. Generally, the light
source is located external to the reaction chamber, and the light
beam enters the reaction chamber through an appropriate window.
[0079] Referring to FIG. 1, a particular embodiment 100 of a laser
pyrolysis apparatus involves a reactant supply system 102, reaction
chamber 104, collection system 106, light source 108 and shielding
gas-delivery system 110. Two alternative reaction supply systems
can be used with the apparatus of FIG. 1. The first reaction supply
system is used to deliver exclusively gaseous reactants. The second
reactant supply system is used to deliver one or more reactants as
an aerosol. Variations on these reaction supply systems can also be
used.
[0080] Referring to FIG. 2, a first embodiment 112 of reactant
supply system 102 includes a source 120 of vanadium precursor
compound. For liquid or solid vanadium precursors, a carrier gas
from carrier gas source 122 can be introduced into precursor source
120 to facilitate delivery of the vanadium precursor as a vapor.
The carrier gas from source 122 preferably is either an infrared
absorber or an inert gas and is preferably bubbled through a liquid
precursor compound or delivered into a solid precursor delivery
system. Inert gas used as a carrier gas can moderate the reaction
conditions. The quantity of precursor vapor in the reaction zone is
roughly proportional to the flow rate of the carrier gas.
[0081] Alternatively, carrier gas can be supplied directly from
infrared absorber source 124 or inert gas source 126, as
appropriate An additional reactant, such as an oxygen source, is
supplied from reactant source 128, which can be a gas cylinder or
other suitable container. The gases from the precursor source 120
are mixed with gases from reactant source 128, infrared absorber
source 124 and inert gas source 126 by combining the gases in a
single portion of tubing 130. The gases are combined a sufficient
distance from reaction chamber 104 such that the gases become well
mixed prior to their entrance into reaction chamber 104.
[0082] The combined gas in tube 130 passes through a duct 132 into
rectangular channel 134, which forms part of an injection nozzle
for directing reactants into the reaction chamber. Portions of
reactant supply system 112 can be heated to inhibit the deposition
of precursor compound on the walls of the delivery system.
[0083] A metal precursor can be supplied from metal precursor
source 138, which can be a liquid reactant delivery apparatus, a
solid reactant delivery apparatus, a gas cylinder or other suitable
container or containers. If metal precursor source 138 delivers a
liquid or solid reactant, carrier gas from carrier gas source 122
or an alternative carrier gas source can be used to facilitate
delivery of the reactant. As shown in FIG. 2, metal precursor
source 138 delivers a metal precursor to duct 132 by way of tubing
130.
[0084] Flow from sources 122, 124, 126 and 128 are preferably
independently controlled by mass flow controllers 136. Mass flow
controllers 136 preferably provide a controlled flow rate from each
respective source. Suitable mass flow controllers include, for
example, Edwards Mass Flow Controller, Model 825 series, from
Edwards High Vacuum International, Wilmington, Mass.
[0085] Referring to FIG. 3A, an alternative embodiment 150 of the
reactant supply system 102 is used to supply an aerosol to channel
134. As described above, channel 134 forms part of an injection
nozzle for directing reactants into the reaction chamber through
the reactant inlet. Reactant supply system 150 includes an aerosol
generator 152, carrier gas/vapor supply tube 154 and junction 156.
Channel 134, aerosol generator 152 and supply tube 154 meet within
interior volume 158 of junction 156. Supply tube 154 is oriented to
direct carrier gas along channel 134. Aerosol generator 152 is
mounted such that an aerosol 160 is generated in the volume of
chamber 158 between the opening into channel 134 and the outlet
from supply tube 154.
[0086] Aerosol generator 152 can operate based on a variety of
principles. For example, the aerosol can be produced with an
ultrasonic nozzle, with an electrostatic spray system, with a
pressure-flow or simplex atomizer, with an effervescent atomizer or
with a gas atomizer where liquid is forced under significant
pressure through a small orifice and sheared into droplets by a
colliding gas stream. Suitable ultrasonic nozzles can include
piezoelectric transducers. Ultrasonic nozzles with piezoelectric
transducers and suitable broadband ultrasonic generators are
available from Sono-Tek Corporation, Milton, N.Y., such as model
8700-120. Suitable aerosol generators are described further in
copending and commonly assigned, U.S. patent application Ser. No.
09/188,670 to Gardner et al., entitled "REACTANT DELIVERY
APPARATUSES," incorporated herein by reference. Additional aerosol
generators can be attached to junction 156 through other ports 162
such that additional aerosols can be generated in interior 158 for
delivery into the reaction chamber.
[0087] Junction 156 includes ports 162 to provide access from
outside junction 156 to interior 158. Thus, channel 134, aerosol
generator 152 and supply Tube 154 can be mounted appropriately. In
one embodiment, junction 156 is cubic with six cylindrical ports
162, with one port 162 extending from each face of junction 156.
Junction 156 can be made from stainless steel or other durable,
noncorrosive material. A window 161 preferably is sealed at one
port 162 to provide for visual observation into interior 158. The
port 162 extending from the bottom of junction 156 preferably
includes a drain 163, such that condensed aerosol that is not
delivered through channel 134 can be removed from junction 156.
[0088] Carrier gas/vapor supply tube 154 is connected to gas source
164. Gas source 164 can include a plurality of gas containers,
liquid reactant delivery apparatuses, and/or a solid reactant
delivery apparatuses, which are connected to deliver a selected gas
or gas mixture to supply tube 154. Thus, carrier gas/vapor supply
tube 154 can be used to deliver a variety of desired gases and/or
vapors within the reactant stream including, for example, laser
absorbing gases, reactants, and/or inert gases. The flow of gas
from gas source 164 to supply tube 154 preferably is controlled by
one or more mass flow controllers 166. Liquid supply tube 168 is
connected to aerosol generator 152. Liquid supply tube 168 is
connected to liquid supply 170.
[0089] For the production of vanadium oxide particles, liquid
supply 170 can hold a liquid comprising a vanadium precursor. For
the production of metal vanadium oxide particles, liquid supply 170
preferably holds a liquid comprising both a vanadium precursor and
a metal precursor. Alternatively, for the production of metal
vanadium oxide particles, liquid supply 170 can hold a liquid
comprising metal precursor while vanadium precursor is delivered by
way of vapor supply tube 154 and gas source(s) 164. Similarly, if
desired, liquid supply 170 can hold a liquid comprising vanadium
precursor, while metal precursor is delivered by way of vapor
supply tube 154 and gas source(s) 164. Also, two separate aerosol
generators 152 can be used to generate aerosol within junction 156,
with one producing an aerosol with vanadium precursor and the
second producing aerosol with the metal precursor.
[0090] In the embodiment shown in FIG. 3, aerosol generator 152
generates an aerosol with momentum roughly orthogonal to the
carrier gas flow from tube 154 to channel 134. Thus, carrier
gas/vapor from supply tube 154 directs aerosol precursor generated
by aerosol generator 152 into channel 134. In operation, carrier
gas flow directs the aerosol delivered within chamber 158 into
channel 134. In this way, the delivery velocity of the aerosol is
determined effectively by the flow rate of the carrier gas.
[0091] In alternative preferred embodiments, the aerosol generator
is placed at an upward angle relative to the horizontal, such that
a component of the forward momentum of the aerosol is directed
along channel 134. In a preferred embodiment, the output directed
from the aerosol generator is placed at about a 45.degree. angle
relative to the normal direction defined by the opening into
channel 134, i.e. the direction of the flow into channel 134 from
supply tube 154.
[0092] Referring to FIG. 3B, another embodiment 172 of the reactant
supply system 102 can be used to supply an aerosol to channel 134.
Reactant supply system 172 includes an outer nozzle 174 and an
inner nozzle 176. Outer nozzle 174 has an upper channel 178 that
leads to a 5/8 in. by 1/4 in. rectangular outlet 180 at the top of
outer nozzle 174, as shown in the insert in FIG. 3B. Outer nozzle
174 includes a drain tube 183 in base plate 184. Drain tube 183 is
used to remove condensed aerosol from outer nozzle 174. Inner
nozzle 176 is secured to outer nozzle 174 at fitting 185.
[0093] Inner nozzle 176 is a gas atomizer from Spraying Systems
(Wheaton, Ill.). The inner nozzle has about a 0.5 inch diameter and
a 12.0 inch length. The top of the nozzle is a twin orifice
internal mix atomizer 186 (0.055 in. gas oriface and 0.005 in.
liquid oriface). Liquid is fed to the atomizer through tube 187,
and gases for introduction into the reaction chamber are fed to the
atomizer through tube 188. Interaction of the gas with the liquid
assists with droplet formation.
[0094] Outer nozzle 174 and inner nozzle 176 are assembled
concentrically. Outer nozzle 174 shapes the aerosol generated by
inner nozzle 176 such that it has a flat rectangular cross section.
In addition, outer nozzle 174 helps to achieve a uniform aerosol
velocity and a uniform aerosol distribution along the cross
section. Outer nozzle 174 can be reconfigured for different
reaction chambers.
[0095] Referring to FIG. 1, shielding gas delivery system 110
includes inert gas source 190 connected to an inert gas duct 192.
Inert gas duct 192 flows into annular channel 194. A mass flow
controller 196 regulates the flow of inert gas into inert gas duct
192. If reactant delivery system 112 is used, inert gas source 126
can also function as the inert gas source for duct 192, if
desired.
[0096] The reaction chamber 104 includes a main chamber 200.
Reactant supply system 102 connects to the main chamber 200 at
injection nozzle 202. Reaction chamber 104 can be heated to keep
the precursor compound in the vapor state. Similarly, the argon
shielding gas preferably can be heated. The chamber can be examined
for condensation to ensure that precursor is not deposited in the
chamber.
[0097] The end of injection nozzle 202 has an annular opening 204
for the passage of inert shielding gas, and a reactant inlet 206
for the passage of reactants to form a reactant stream in the
reaction chamber. Reactant inlet 206 preferably is a slit, as shown
in FIG. 1. Annular opening 204 has, for example, a diameter of
about 1.5 inches and a width along the radial direction from about
1/8 in to about {fraction (1/16)} in. The flow of shielding gas
through annular opening 204 helps to prevent the spread of the
reactant gases and product particles throughout reaction chamber
104.
[0098] Tubular sections 208, 210 are located on either side of
injection nozzle 202. Tubular sections 208, 210 include ZnSe
windows 212, 214, respectively. Windows 212, 214 are about 1 inch
in diameter. Windows 212, 214 are preferably cylindrical lenses
with a focal length equal to the distance between the center of the
chamber to the surface of the lens to focus the beam to a point
just below the center of the nozzle opening. Windows 212, 214
preferably have an antireflective coating. Appropriate ZnSe lenses
are available from Janos Technology, Townshend, Vt. Tubular
sections 208, 210 provide for the displacement of windows 212, 214
away from main chamber 200 such that windows 212, 214 are less
likely to be contaminated by reactants and/or products. Window 212,
214 are displaced, for example, about 3 cm from the edge of the
main chamber 200.
[0099] Windows 212, 214 are sealed with a rubber o-ring to tubular
sections 208, 210 to prevent the flow of ambient air into reaction
chamber 104. Tubular inlets 216, 218 provide for the flow of
shielding gas into tubular sections 208, 210 to reduce the
contamination of windows 212, 214. Tubular inlets 216, 218 are
connected to inert gas source 138 or to a separate inert gas
source. In either case, flow to inlets 216, 218 preferably is
controlled by a mass flow controller 220.
[0100] Light source 108 is aligned to generate a light beam 222
that enters window 212 and exits window 214. Windows 212, 214
define a light path through main chamber 200 intersecting the flow
of reactants at reaction zone 224. After exiting window 214, light
beam 222 strikes power meter 226, which also acts as a beam dump.
An appropriate power meter is available from Coherent Inc., Santa
Clara, Calif. Light source 108 preferably is a laser, although it
can be an intense conventional light source such as an arc lamp.
Preferably, light source 108 is an infrared laser, especially a CW
CO.sub.2 laser such as an 1800 watt maximum power output laser
available from PRC Corp., Landing, N.J. In alternative embodiments,
light source 108 is replaced by another type of electromagnetic
energy source such as a microwave generator. In this embodiment,
the reactant stream includes a radiation absorbing compound, such
as a microwave absorber.
[0101] Reactants passing through reactant inlet 206 in injection
nozzle 202 initiate a reactant stream. The reactant stream passes
through reaction zone 224, where reaction involving the precursor
and additional reactant compound(s) takes place. Heating of the
gases in reaction zone 224 generally is extremely rapid, roughly on
the order of 10.sup.5 degree C/sec depending on the specific
conditions. The reaction is rapidly quenched upon leaving reaction
zone 224, and particles 228 are formed in the reactant stream. The
nonequilibrium nature of the process allows for the production of
nanoparticles with a highly uniform size distribution and
structural homogeneity.
[0102] The path of the reactant/product stream continues to
collection nozzle 230. Collection nozzle 230 is spaced about 2 cm
from injection nozzle 202. The small spacing between injection
nozzle 202 and collection nozzle 230 helps reduce the contamination
of reaction chamber 104 with reactants and products. Collection
nozzle 230 has a circular opening 232. Circular opening 232 feeds
into collection system 106.
[0103] The chamber pressure is monitored with a pressure gauge
attached to the main chamber. The preferred chamber pressure for
the production of the desired oxides generally ranges from about 80
Torr to about 500 Torr.
[0104] Reaction chamber 104 has two additional tubular sections not
shown. One of the additional tubular sections projects into the
plane of the sectional view in FIG. 1, and the second additional
tubular section projects out of the plane of the sectional view in
FIG. 1. When viewed from above, the four tubular sections are
distributed roughly, symmetrically around the center of the
chamber. These additional tubular sections have windows for
observing the inside of the chamber. In this configuration of the
apparatus, the two additional tubular sections are not used to
facilitate production of particles.
[0105] Collection system 106 preferably includes a curved channel
270 leading from collection nozzle 230. Because of the small size
of the particles, the product particles follow the flow of the gas
around curves. Collection system 106 includes a filter 272 within
the gas flow to collect the product particles. Due to curved
section 270, the filter is not supported directly above the
chamber. A variety of materials such as Teflon, glass fibers and
the like can be used for the filter as long as the material is
inert and has a fine enough mesh to trap the particles. Preferred
materials for the filter include, for example, a glass fiber filter
from ACE Glass Inc., Vineland, N.J. and cylindrical Nomex.RTM.
fiber filters from AF Equipment Co., Sunnyvale, Calif.
[0106] Pump 274 is used to maintain collection system 106 at a
selected pressure. A variety of different pumps can be used.
Appropriate pumps for use as pump 274 include, for example, Busch
Model B0024 pump from Busch, Inc., Virginia Beach, Va. with a
pumping capacity of about 25 cubic feet per minute (cfm) and
Leybold Model SV300 pump from Leybold Vacuum Products, Export, Pa.
with a pumping capacity of about 195 cfm. It may be desirable to
flow the exhaust of the pump through a scrubber 276 to remove any
remaining reactive chemicals before venting into the atmosphere.
The entire apparatus 100 can be placed in a fume hood for
ventilation purposes and for safety considerations. Generally, the
laser remains outside of the fume hood because of its large
size.
[0107] The apparatus is controlled by a computer. Generally, the
computer controls the laser and monitors the pressure in the
reaction chamber. The computer can be used to control the flow of
reactants and/or the shielding gas. The pumping rate is controlled
by either a manual needle valve or an automatic throttle valve
inserted between pump 274 and filter 272. As the chamber pressure
increases due to the accumulation of particles on filter 272, the
manual valve or the throttle valve can be adjusted to maintain the
pumping rate and the corresponding chamber pressure.
[0108] The reaction can be continued until sufficient particles are
collected on filter 272 such that the pump can no longer maintain
the desired pressure in the reaction chamber 104 against the
resistance through filter 272. When the pressure in reaction
chamber 104 can no longer be maintained at the desired value, the
reaction is stopped, and filter 272 is removed. With this
embodiment, about 1-300 grams of particles can be collected in a
single run before the chamber pressure can no longer be maintained.
A single run generally can last up to about 10 hours depending on
the reactant delivery system, the type of particle being produced
and the type of filter being used.
[0109] The reaction conditions can be controlled relatively
precisely. In particular, the mass flow controllers are quite
accurate. The laser generally has about 0.5 percent power
stability. With either a manual control or a throttle valve, the
chamber pressure can be controlled to within about 1 percent.
[0110] The configuration of the reactant supply system 102 and the
collection system 106 can be reversed. In this alternative
configuration, the reactants are supplied from the top of the
reaction chamber, and the product particles are collected from the
bottom of the chamber. In this configuration, the collection system
may not include a curved section so that the collection filter is
mounted directly below the reaction chamber.
[0111] An alternative design of a laser pyrolysis apparatus has
been described in copending and commonly assigned U.S. patent
application Ser. No. 08/808,850, entitled "Efficient Production of
Particles by Chemical Reaction," incorporated herein by reference.
This alternative design is intended to facilitate production of
commercial quantities of particles by laser pyrolysis. The reaction
chamber is elongated along the laser beam in a dimension
perpendicular to the reactant stream to provide for an increase in
the throughput of reactants and products. The original design of
the apparatus was based on the introduction of purely gaseous
reactants. Alternative embodiments for the introduction of an
aerosol into an elongated reaction chamber is described in
copending and commonly assigned U.S. patent application Ser. No.
09/188,670 to Gardner et al., filed on Nov. 9, 1998, entitled
"Reactant Delivery Apparatuses," incorporated herein by
reference.
[0112] In general, the alternative pyrolysis apparatus includes a
reaction chamber designed to reduce contamination of the chamber
walls, to increase the production capacity and to make efficient
use of resources. To accomplish these objectives, an elongated
reaction chamber is used that provides for an increased throughput
of reactants and products without a corresponding increase in the
dead volume of the chamber. The dead volume of the chamber can
become contaminated with unreacted compounds and/or reaction
products.
[0113] The design of the improved reaction chamber 300 is shown
schematically in FIGS. 4 and 5. A reactant inlet 302 enters the
main chamber 304. Reactant inlet 302 provides for the introduction
of gaseous and/or aerosol reactants into main chamber 304. Reactant
inlet 302 conforms generally to the shape of main chamber 304. The
introduction of reactants through reactant inlet 302 for the
production of vanadium oxide particles or metal vanadium oxide
particles can be performed by following the discussion above
regarding the introduction of aerosol and/or vapor precursors with
the laser pyrolysis apparatus of FIG. 1, appropriately adapted for
the alternative structure of the reactant inlet.
[0114] Main chamber 304 includes an outlet 306 along the
reactant/product stream for removal of particulate products, any
unreacted gases and inert gases. Shielding gas inlets 310 are
located on both sides of reactant inlet 302. Shielding gas inlets
are used to form a blanket of inert gases on the sides of the
reactant stream to inhibit contact between the chamber walls and
the reactants and products.
[0115] Tubular sections 320, 322 extend from the main chamber 304.
Tubular sections 320, 322 hold windows 324, 326 to define a laser
beam path 328 through the reaction chamber 300. Tubular sections
320, 322 can include inert gas inlets 330, 332 for the introduction
of inert gas into tubular sections 320, 322.
[0116] The dimensions of elongated reactant inlet 316 preferably
are designed for high efficiency particle production. Reasonable
dimensions for the reactant inlet for the production of vanadium
oxide nanoparticles and metal vanadium oxide nanoparticles, when
used with a 1800 watt CO.sub.2 laser, are from about 5 mm to about
1 meter.
[0117] The improved apparatus includes a collection system to
remove the nanoparticles from the molecular stream. The collection
system can be designed to collect a large quantity of particles
without terminating production or, preferably, to run in continuous
production by switching between different particle collectors
within the collection system. The collection system can include
curved components within the flow path similar to curved portion of
the collection system shown in FIG. 1.
[0118] A preferred embodiment of a collection system for particle
production systems operating in a continuous collection mode is
described in copending and commonly assigned U.S. patent
application Ser. No. 09/107,729 to Gardner et al., entitled
"Particle Collection Apparatus And Associated Methods,"
incorporated herein by reference. A batch collection system for use
with the improved reaction system is described in copending and
commonly assigned U.S. patent application Ser. No. 09/188,770,
filed on Nov. 9, 1998, entitled "Metal Oxide Particles,"
incorporated herein by reference. The configuration of the reactant
injection components and the collection system can be reversed such
that the particles are collected at the top of the apparatus.
[0119] As noted above, properties of the vanadium oxide particles
and metal vanadium oxide particles can be modified by further
processing. Suitable starting material for the heat treatment
include vanadium oxide particles and metal vanadium oxide particles
produced by laser pyrolysis. Suitable vanadium oxide materials
include, for example, VO, VO.sub.1.27, VO.sub.2, V.sub.2O.sub.3,
V.sub.3O.sub.5, V.sub.4O.sub.9, V.sub.6O.sub.13, and amorphous
V.sub.2O.sub.5. Similarly, the starting materials can be metal
vanadium oxide particles, such as silver vanadium oxide particles
and/or copper vanadium oxide particles produced by laser pyrolysis.
Suitable metal vanadium oxide materials include
Ag.sub.2V.sub.4O.sub.11 and a new crystalline form of silver
vanadium oxide described in the Examples below. In addition,
particles used as starting material can have been subjected to one
or more prior heating steps under different conditions.
[0120] The starting materials generally can be particles of any
size and shape, although nanoscale particles are preferred starting
materials. The nanoscale particles have an average diameter of less
than about 1000 nm and preferably from about 5 nm to about 500 nm,
and more preferably from about 5 nm to about 150 nm. Suitable
nanoscale starting materials have been produced by laser
pyrolysis.
[0121] The vanadium oxide particles or metal vanadium oxide
particles are preferably heated in an oven or the like to provide
generally uniform heating. The processing conditions generally are
mild, such that significant amounts of particle sintering does not
occur. The temperature of heating preferably is low relative to the
melting point of both the starting material and the product
material.
[0122] For certain target product particles, additional heating
does not lead to further variation in the particle composition once
equilibrium has been reached. The atmosphere for the heating
process can be an oxidizing atmosphere or an inert atmosphere. In
particular, for conversion of amorphous particles to crystalline
particles or from one crystalline structure to a different
crystalline structure of essentially the same stoichiometry, the
atmosphere generally can be inert. The atmosphere over the
particles can be static, or gases can be flowed through the
system.
[0123] Appropriate oxidizing gases include, for example, O.sub.2,
O.sub.3, CO, CO.sub.2, and combinations thereof. The O.sub.2 can be
supplied as air. Oxidizing gases optionally can be mixed with inert
gases such as Ar, He and N.sub.2. When inert gas is mixed with the
oxidizing gas, the gas mixture can include from about 1 percent
oxidizing gas to about 99 percent oxidizing gas, and more
preferably from about 5 percent oxidizing gas to about 99 percent
oxidizing gas. Alternatively, either essentially pure oxidizing gas
or pure inert gas can be used, as desired.
[0124] The precise conditions can be altered to vary the type of
vanadium oxide product or metal vanadium oxide produce that is
produced. For example, the temperature, time of heating, heating
and cooling rates, the gases and the exposure conditions with
respect to the gases can all be changed, as desired. Generally,
while heating under an oxidizing atmosphere, the longer the heating
period the more oxygen that is incorporated into the material,
prior to reaching equilibrium. Once equilibrium conditions are
reached, the overall conditions determine the crystalline phase of
the powders.
[0125] A variety of ovens or the like can be used to perform the
heating. An example of an apparatus 400 to perform this processing
is displayed in FIG. 6. Apparatus 400 includes a jar 402, which can
be made from glass or other inert material, into which the
particles are placed. Suitable glass reactor jars are available
from Ace Glass (Vineland, N.J.). The top of glass jar 402 is sealed
to a glass cap 404, with a Teflon.RTM. gasket 405 between jar 402
and cap 404. Cap 404 can be held in place with one or more clamps.
Cap 404 includes a plurality of ports 406, each with a Teflon.RTM.
bushing. A multiblade stainless steel stirrer 408 preferably is
inserted through a central port 406 in cap 404. Stirrer 408 is
connected to a suitable motor.
[0126] One or more tubes 410 are inserted through ports 406 for the
delivery of gases into jar 402. Tubes 410 can be made from
stainless steel or other inert material. Diffusers 412 can be
included at the tips of tubes 410 to disburse the gas within jar
402. A heater/furnace 414 generally is placed around jar 402.
Suitable resistance heaters are available from Glas-col (Terre
Haute, Ind.). One port preferably includes a T-connection 416. The
temperature within jar 402 can be measured with a thermocouple 416
inserted through T-connection 416. T-connection 416 can be further
connected to a vent 418. Vent 418 provides for the venting of gas
circulated through jar 402. Preferably vent 418 is vented to a fume
hood or alternative ventilation equipment.
[0127] Preferably, desired gases are flowed through jar 402. Tubes
410 generally are connected to an oxidizing gas source and/or an
inert gas source. Oxidizing gas, inert gas or a combination thereof
to produce the desired atmosphere are placed within jar 402 from
the appropriate gas source(s). Various flow rates can be used. The
flow rate preferably is between about 1 standard cubic centimeters
per minute (sccm) to about 1000 sccm and more preferably from about
10 sccm to about 500 scam. The flow rate generally is constant
through the processing step, although the flow rate and the
composition of the gas can be varied systematically over time
during processing, if desired. Alternatively, a static gas
atmosphere can be used.
[0128] VO.sub.2, a material with a high melting point, is
relatively easy to form in the laser pyrolysis apparatuses
described above. VO.sub.2 is a suitable starting product for
oxidation to other forms of vanadium oxide. Some empirical
adjustment may be required to produce the conditions appropriate to
generate a desired material. In addition, the heat processing can
result in an alteration of the crystal lattice and/or removal of
adsorbed compounds on the particles to improve the quality of the
particles.
[0129] For the processing of vanadium oxide nanoparticles or metal
vanadium oxide nanopartlcles, for example, the temperatures
preferably range from about 50.degree. C. to about 500.degree. C.
and more preferably from about 60.degree. C. to about 400.degree.
C. The heating preferably is continued for greater than about 5
minutes, and generally is continued for from about 2 hours to about
100 hours, preferably from about 2 hours to about 50 hours. Some
empirical adjustment may be required to produce the conditions
appropriate for yielding a desired material. The use of mild
conditions avoids interparticle sintering resulting in larger
particle sizes. Some controlled sintering of the particles can be
performed at somewhat higher temperatures to produce slightly
larger, average particle diameters.
[0130] The conditions to convert crystalline VO.sub.2 to
orthorhombic V.sub.2O.sub.5 and 2-D crystalline V.sub.2O.sub.5, and
amorphous V.sub.2O.sub.5, to orthorhombic V.sub.2O.sub.5 and 2-D
crystalline V.sub.2O.sub.5 are describe in copending and commonly
assigned U.S. patent application Ser. No. 08/897,903, to Bi et al.,
entitled "Processing of Vanadium Oxide Particles With Heat,"
incorporated herein by reference.
[0131] B. Thermal Processing for the Formation of Metal Vanadium
Oxide Particles
[0132] While metal vanadium oxide particles can be produced
directly through laser pyrolysis, as described above, it has been
discovered that heat processing also can be used to form nanoscale
metal vanadium oxide particles. In a preferred approach to the
thermal formation of metal vanadium oxide particles, vanadium oxide
nanoscale particles first are mixed with a non-vanadium metal
compound. The resulting mixture as heated in an oven to form a
metal vanadium oxide composition. The heat processing to
incorporate metal into the vanadium oxide lattice can be performed
in an oxidizing environment or an inert environment. In either type
of environment, the heating step generally results in alteration of
the oxygen to vanadium ratio. In addition, the heat processing can
result in an alteration of the crystal lattice and/or removal of
adsorbed compounds on the particles to improve the quality of the
particles.
[0133] The use of sufficiently mild conditions, i.e., temperatures
well below the melting point of the vanadium oxide particles,
results in metal incorporation into the vanadium oxide particles
without significantly sintering the particles into larger
particles. The vanadium oxide particles used for the process
preferably are nanoscale vanadium oxide particles. It has been
discovered that metal vanadium oxide compositions can be formed
from vanadium oxides with an oxidation state of +5 or less than +5.
In particular, vanadium oxides with an oxidation states from +2
(VO) to +5 (V.sub.2O.sub.5) can be used to form metal vanadium
oxide particles.
[0134] Generally, the metal incorporated into the metal vanadium
oxide particle is any non-vanadium transition metal. Preferred
metals for incorporation into the vanadium oxide include, for
example, copper, silver, gold, and combinations thereof. Suitable
silver compounds include, for example, silver nitrate (AgNO.sub.3).
Suitable copper compounds include, for example, cupric nitrate
(Cu(NO.sub.3).sub.2). Alternatively, silver metal powder, copper
metal powder or gold metal powder can be used as sources of the
respective metals.
[0135] Appropriate oxidizing gases include, for example, O.sub.2
(supplied as airs if desired), O.sub.3, CO, CO.sub.2 and
combinations thereof. The reactant gas can be diluted with inert
gases such as Ar, He and N.sub.2. Alternatively, the gas atmosphere
can be exclusively inert gas. Silver vanadium oxide particles have
been produced with either an inert atmosphere or an oxidizing
atmosphere, as described in the Examples below.
[0136] A variety of apparatuses can be used to perform the heat
processing for lithiation and/or annealing of a sample. An
embodiment of a suitable apparatus 400 is described above with
respect to FIG. 6 for the heat processing of vanadium oxides
produced by laser pyrolysis. An alternative apparatus 430 for the
incorporation of a metal into the vanadium oxide lattice is shown
in FIG. 7. The particles are placed within a small vial 432, boat
or the like within tube 434. Preferably, the desired gases are
flowed through tube 434. Gases can be supplied for example from
inert gas source 436 or oxidizing gas source 438.
[0137] Tube 434 is located within oven or furnace 440. Oven 440 can
be adapted from a commercial furnace, such as Mini-Mite.TM.
1100.degree. C. Tube Furnace from Lindberg/Blue M, Asheville, N.C.
Oven 440 maintains the relevant portions of the tube at a
relatively constant temperature, although the temperature can be
varied systematically through the processing step, if desired. The
temperature can be monitored with a thermocouple 442.
[0138] To form metal vanadium oxide particles in the heating step,
a mixture of vanadium oxide particles and the metal compound can be
placed in tube 434 within a vial 432, boat or the like. Preferably,
a solution of the metal compound is mixed with the vanadium oxide
nanoparticles and evaporated to dryness prior to further heating in
the oven. The evaporation can be performed simultaneously with the
heating to form the metal vanadium oxide composition, if desired.
For example, silver nitrate and copper nitrate can be applied to
the vanadium oxide particles as an aqueous solution. Alternatively,
vanadium oxide nanoparticles can be mixed with a dry powder of the
metal compound or elemental metal powder, thereby avoiding the
evaporation step. A sufficient amount of the metal compound or
elemental metal powder is added to yield the desired amount of
incorporation of the metal into the vanadium oxide lattice. This
incorporation into the vanadium oxide lattice can be checked, for
example, through the use of x-ray diffractometry, as described
below.
[0139] The precise conditions including type of oxidizing gas (if
any), concentration of oxidizing gas, pressure or flow rate of gas,
temperature and processing time can be selected to produce the
desired type of product material. The temperatures generally are
mild, i.e., significantly below the melting point of the materials.
The use of mild conditions avoids interparticle sintering resulting
in larger particle sizes. Some controlled sintering of the
particles can be performed in the oven at somewhat higher
temperatures to produce slightly larger, average particle
diameters.
[0140] For the metal incorporation into vanadium oxide, the
temperature generally ranges from about 50.degree. C. to about
500.degree. C., preferably from about 80.degree. C. to about
400.degree. C., and more preferably from about 80.degree. C. to
about 325.degree. C. The processing temperature can range from
about 80.degree. C. to about 250.degree. C. The particles
preferably are heated for about 5 minutes to about 100 hours. Some
empirical adjustment may be required to produce the conditions
appropriate for yielding a desired material.
[0141] C. Particle Properties
[0142] A collection of particles of interest, comprising metal
vanadium oxide compounds, generally has an average diameter for the
primary particles of less than about 500 nm, preferably from about
5 nm to about 100 nm, more preferably from about 5 nm to about 50
nm, and even more preferably from about 5 nm to about 25 nm. The
primary particles usually have a roughly spherical gross
appearance. Upon closer examination, crystalline particles
generally have facets corresponding to the underlying crystal
lattice. Nevertheless, crystalline primary particles tend to
exhibit growth that is roughly equal in the three physical
dimensions to give a gross spherical appearance. In preferred
embodiments, 95 percent of the primary particles, and preferably 99
percent, have ratios of the dimension along the major axis to the
dimension along the minor axis less than about 2. Diameter
measurements on particles with asymmetries are based on an average
of length measurements along the principle axes of the
particle.
[0143] Because of their small size, the primary particles tend to
form loose agglomerates due to van der Waals and other
electromagnetic forces between nearby particles. Nevertheless, the
nanometer scale of the primary particles is clearly observable in
transmission electron micrographs of the particles. The particles
generally have a surface area corresponding to particles on a
nanometer scale as observed in the micrographs. Furthermore, the
particles can manifest unique properties due to their small size
and large surface area per weight of material. For example,
vanadium oxide nanoparticles generally exhibit surprisingly high
energy densities in lithium batteries, as described in copending
and commonly assigned U.S. patent application Ser. No. 08/897,776,
entitled "Batteries With Electroactive Nanoparticles," incorporated
herein by reference.
[0144] The primary particles preferably have a high degree of
uniformity in size. Laser pyrolysis, as described above, generally
results in particles having a very narrow range of particle
diameters. Furthermore, heat processing under mild conditions does
not alter the very narrow range of particle diameters. With aerosol
delivery, the distribution of particle diameters is particularly
sensitive to the reaction conditions. Nevertheless, if the reaction
conditions are properly controlled, a very narrow distribution of
particle diameters can be obtained with an aerosol delivery system,
as described above. As determined from examination of transmission
electron micrographs, the primary particles generally have a
distribution in sizes such that at least about 95 percent, and
preferably 99 percent, of the primary particles have a diameter
greater than about 40 percent of the average diameter and less than
about 160 percent of the average diameter. Preferably, the primary
particles have a distribution of diameters such that at least about
95 percent, and preferably 99 percent, of the primary particles
have a diameter greater than about 60 percent of the average
diameter and less than about 140 percent of the average
diameter.
[0145] Furthermore, in preferred embodiments no primary particles
have an average diameter greater than about 4 times the average
diameter and preferably 3 times the average diameter, and more
preferably 2 times the average diameter. In other words, the
particle size distribution effectively does not have a tail
indicative of a small number of particles with significantly larger
sizes. This is a result of the small reaction region and
corresponding rapid quench of the particles. An effective cut off
in the tail of the size distribution indicates that there are less
than about 1 particle in 10.sup.6 have a diameter greater than a
specified cut off value above the average diameter. Narrow size
distributions, lack of a tail in the distributions and the roughly
spherical morphology can be exploited in a variety of
applications.
[0146] In addition, the nanoparticles generally have a very high
purity level. The crystalline metal vanadium oxide nanoparticles
produced by the above described methods are expected to have a
purity greater than the reactants because the crystal formation
process tends to exclude contaminants from the lattice.
Furthermore, crystalline vanadium oxide particles produced by laser
pyrolysis have a high degree of crystallinity. Similarly, the
crystalline metal vanadium oxide nanoparticles produced by heat
processing have a high degree of crystallinity. Impurities on the
surface of the particles may be removed by heating the particles to
achieve not only high crystalline purity but high purity
overall.
[0147] Vanadium oxide has an intricate phase diagram due to the
many possible oxidation states of vanadium. Vanadium is known to
exist in oxidation states between V.sup.+2 and V.sup.+5. The energy
differences between the oxides of vanadium in the different
oxidation states is not large. Therefore, it is possible to produce
stoichiometric mixed valence compounds. Known forms of vanadium
oxide include VO, VO.sub.1.27, V.sub.2O.sub.3, V.sub.3O.sub.5,
VO.sub.2, V.sub.6O.sub.13, V.sub.4O.sub.9, V.sub.3O.sub.7, and
V.sub.2O.sub.5. Laser pyrolysis alone or with additional heating
can successfully yield single phase vanadium oxide in many
different oxidation states, as evidenced by x-ray diffraction
studies. These single phase materials are generally crystalline,
although some amorphous nanoparticles have been produced. The heat
treatment approaches are useful for increasing the oxidation state
of vanadium oxide particles or for converting vanadium oxide
particles to more ordered phases.
[0148] There are also mixed phase regions of the vanadium oxide
phase diagram. In the mixed phase regions, particles can be formed
that have domains with different oxidation states, or different
particles can be simultaneously formed with vanadium in different
oxidation states. In other words, certain particles or portions of
particles have one stoichiometry while other particles or portions
of particles have a different stoichiometry. Mixed phase
nanoparticles have been formed. Non-stoichiometric materials also
can be formed.
[0149] The vanadium oxides generally form crystals with octahedral
or distorted octahedral coordination. Specifically, VO,
V.sub.2O.sub.3, VO.sub.2, V.sub.6O.sub.13 V.sub.3O.sub.7 can form
crystals with octahedral coordination. In addition, V.sub.3O.sub.7
can form crystals with trigonal bipyramidal coordination.
V.sub.2O.sub.5 forms crystals with square pyramidal crystal
structure. V.sub.2O.sub.5 recently also has been produced in a two
dimensional crystal structure. See, M. Hibino, et al., Solid State
Ionics 79:239-244 (1995), incorporated herein by reference. When
produced under appropriate conditions, the vanadium oxide
nanoparticles can be amorphous. The crystalline lattice of the
vanadium oxide can be evaluated using x-ray diffraction
measurements.
[0150] Metal vanadium oxide compounds can be formed with various
stoichiometries. U.S. Pat. No. 4,310,609 to Liang et al., entitled
"Metal Oxide Composite Cathode Material for High Energy Density
Batteries," incorporated herein by reference, describes the
formation of Ag.sub.0.7V.sub.2O.sub.5.5, AgV.sub.2O.sub.5.5, and
Cu.sub.0.7V.sub.2O.sub.5.5. The production of oxygen deficient
silver vanadium oxide, Ag.sub.0.7V.sub.2O.sub.5, is described in
U.S. Pat. No. 5,389,472 to Takeuchi et al., entitled "Preparation
of Silver Vanadium Oxide Cathodes Using Ag(O) and V.sub.2O.sub.5 as
Starting Materials," incorporated herein by reference. The phase
diagram of silver vanadium oxides of the formula
Ag.sub.xV.sub.2O.sub.y, 0.3.ltoreq.x.ltoreq.2.0,
4.5.ltoreq.y.ltoreq.6.0, involving stoichiometric admixtures of
V.sub.2O.sub.5 and AgVO.sub.3, are described in published European
Patent Application 0 689 256A, entitled "Cathode material for
nonaqueous electrochemical cells," incorporated herein by
reference.
[0151] D. Batteries
[0152] Referring to FIG. 8, battery 450 has an negative electrode
452, a positive electrode 454 and separator 456 between negative
electrode 452 and positive electrode 454. A single battery can
include multiple positive electrodes and/or multiple negative
electrodes. Electrolyte can be supplied in a variety of ways as
described further below. Battery 450 preferably includes current
collectors 458, 460 associated with negative electrode 452 and
positive electrode 454, respectively. Multiple current collectors
can be associated with each electrode if desired.
[0153] Lithium has been used in reduction/oxidation reactions in
batteries because it is the lightest metal and because it is the
most electropositive metal. Certain forms of metal oxides are known
to incorporate lithium ions into its structure through
intercalation or similar mechanisms such as topochemical
absorption. Intercalation of lithium ions can take place also into
suitable forms of a vanadium oxide lattice as well as the lattice
of metal vanadium oxide compositions. Suitable metal vanadium oxide
nanoparticles for incorporation into batteries can be produced by
thermal processing of vanadium oxide nanoparticles with a metal
compound or by direct laser pyrolysis synthesis of metal vanadium
oxide nanoparticles with or without additional heat processing.
[0154] In particular, lithium intercalates into the vanadium oxide
lattice or metal vanadium oxide lattice during discharge of the
battery. The lithium leaves the lattice upon recharging, i.e., when
a voltage is applied to the cell such that electric current flows
into the positive electrode due to the application of an external
EMF to the battery. Positive electrode 454 acts as a cathode during
discharge, and negative electrode 452 acts as an anode during
discharge of the cell. Metal vanadium oxide particles can be used
directly in a positive electrode for a lithium based battery to
provide a cell with a high energy density. Appropriate metal
vanadium oxide particles can be an effective electroactive material
for a positive electrode in either a lithium or lithium ion
battery.
[0155] Positive electrode 454 includes electroactive nanoparticles
such as metal vanadium oxide nanoparticles held together with a
binder such as a polymeric binder. Nanoparticles for use in
positive electrode 454 generally can have any shape, e.g., roughly
spherical nanoparticles or elongated nanoparticles. In addition to
metal vanadium oxide particles, positive electrode 454 can include
other electroactive nanoparticles such as TiO.sub.2 nanoparticles,
vanadium oxide nanoparticles and manganese oxide nanoparticles. The
production of TiO.sub.2 nanoparticles has been described, see U.S.
Pat. No. 4,705,762, incorporated herein by reference. Vanadium
oxide nanoparticles are know to exhibit surprisingly high energy
densities, as described in copending and commonly assigned U.S.
patent application Ser. No. 08/897,776, entitled "Batteries With
Electroactive Nanoparticles," incorporated herein by reference. The
production of manganese oxide nanoparticles is described in
copending and commonly assigned U.S. patent application Ser. No.
09/188,770 to Kumar et al. filed on Nov. 9, 1998, entitled "Metal
Oxide Particles," incorporated herein by reference.
[0156] While some electroactive materials are reasonable electrical
conductors, a positive electrode generally includes electrically
conductive particles in addition to the electroactive
nanoparticles. These supplementary, electrically conductive
particles generally are also held by the binder. Suitable
electrically conductive particles include conductive carbon
particles such as carbon black, metal particles such as silver
particles, metal fibers such as stainless steel fibers, and the
like.
[0157] High loadings of particles can be achieved in the binder.
Particles preferably make up greater than about 80 percent by
weight of the positive electrode, and more preferably greater than
about 90 percent by weight. The binder can be any of various
suitable polymers such as polyvinylidene fluoride, polyethylene
oxide, polyethylene, polypropylene, polytetrafluoro ethylene,
polyacrylates, ethylene-(propylene-diene monomer) copolymer (EPDM)
and mixtures and copolymers thereof.
[0158] Negative electrode 452 can be constructed from a variety of
materials that are suitable for use with lithium ion electrolytes.
In the case of lithium batteries, the negative electrode can
include lithium metal or lithium alloy metal either in the form of
a foil, grid or metal particles in a binder.
[0159] Lithium ion batteries use particles of a composition that
can intercalate lithium. The particles are held with a binder in
the negative electrode. Suitable intercalation compounds include,
for example, graphite, synthetic graphite, coke, mesocarbons, doped
carbons, fullerenes, niobium pentoxide, tin alloys, SnO.sub.2 and
mixtures and composites thereof.
[0160] Current collectors 458, 460 facilitate flow of electricity
from battery 450. Current collectors 458, 460 are electrically
conductive and generally made of metal such as nickel, iron,
stainless steel, aluminum and copper and can be metal foil or
preferably a metal grid. Current collector 458, 460 can be on the
surface of their associated electrode or embedded within their
associated electrode.
[0161] Separator element 456 is electrically insulating and
provides for passage of at least some types of ions. Ionic
transmission through the separator provides for electrical
neutrality in the different sections of the cell. The separator
generally prevents electroactive compounds in the positive
electrode from contacting electroactive compounds in the negative
electrode.
[0162] A variety of materials can be used for the separator. For
example, the separator can be formed from glass fibers that form a
porous matrix. Preferred separators are formed from polymers such
as those suitable for use as binders. Polymer separators can be
porous to provide for ionic conduction. Alternatively, polymer
separators can be solid electrolytes formed from polymers such as
polyethylene oxide. Solid electrolytes incorporate electrolyte into
the polymer matrix to provide for ionic conduction without the need
for liquid solvent.
[0163] Electrolytes for lithium batteries or lithium ion batteries
can include any of a variety of lithium salts. Preferred lithium
salts have inert anions and are nontoxic. Suitable lithium salts
include, for example, lithium hexafluorophosphate, lithium
hexafluoroarsenate, lithiumbis(trifluoromethylsulfonyl imide),
lithium trifluoromethane sulfonate, lithium tris(trifluoromethyl
sulfonyl) methide, lithium tetrafluoroborate, lithium perchlorate,
lithium tetrachloroaluminate, lithium chloride and lithium
perfluorobutane.
[0164] If a liquid solvent is used to dissolve the electrolyte, the
solvent preferably is inert and does not dissolve the electroactive
materials. Generally appropriate solvents include, for example,
propylene carbonate, dimethyl carbonate, diethyl carbonate,
2-methyl tetrahydrofuran, dioxolane, tetrahydrofuran, 1,
2-dimethoxyethane, ethylene carbonate, .gamma.-butyrolactone,
dimethyl sulfoxide, acetonitrile, formamide, dimethyl formamide and
nitromethane.
[0165] The shape of the battery components can be adjusted to be
suitable for the desired final product, for example, a coin
battery, a rectangular construction or a cylindrical battery. The
battery generally includes a casing with appropriate portions in
electrical contact with current collectors and/or electrodes of the
battery. If a liquid electrolyte is used, the casing should prevent
the leakage of the electrolyte. The casing can help to maintain the
battery elements in close proximity to each other to reduce
resistance within the battery. A plurality of battery cells can be
placed in a single case with the cells connected either in series
or in parallel.
EXAMPLES
Example 1
Production of Vanadium Oxide by Laser Pyrolysis
[0166] Single phase VO.sub.2 particles were produced by laser
pyrolysis. The VOCl.sub.3 (Strem Chemical, Inc., Newburyport,
Mass.) precursor vapor was carried into the reaction chamber by
bubbling Ar gas through the VOCl.sub.3 liquid stored in a container
at room temperature. The reactant gas mixture containing
VOCl.sub.3, Ar, O.sub.2 and C.sub.2H.sub.4 was introduced into the
reactant gas nozzle for injection into the reactant chamber. The
reactant gas nozzle had dimensions 5/8 in.times.1/8 in.
C.sub.2H.sub.4 gas was used as a laser absorbing gas. Argon was
used as an inert gas.
[0167] The synthesized vanadium oxide nanoscale particles can be
directly handled in the air. Representative reaction conditions for
the production of this material are described in Table 1.
1 TABLE 1 Phase VO.sub.2 Crystal Monoclinic Structure Pressure 210
(Torr) Argon-Win 700 (sccm) Argon-Sld. 7.0 (slm) Ethylene (slm)
1.61 Carrier Gas- 1.4 Argon (slm) Oxygen (slm) 0.47 Precursor 40
Temp. (.degree. C.) Production 35 Rate (gm/hr) Laser Power- 780
Input (watts) Laser Power- 640 Output (watts) sccm = standard cubic
centimeters per minute slm = standard liters per minute Argon-Win.
= argon flow through inlets 216, 218 Argon-Sid. = argon flow
through annular channel 142
[0168] An x-ray diffractogram of representative product
nanoparticles is shown in FIG. 9. Clear diffraction peaks
corresponding to a monoclinic crystalline structure are visible.
The identified structure from the diffractogram is almost identical
to that of the corresponding bulk material, which has larger
particle sizes.
Example 2
Heat Treatment to Form Crystalline V.sub.2O.sub.5 Nanoparticles
[0169] The starting materials for the heat treatment were VO.sub.2
nanoparticles produced by laser pyrolysis according to the
parameters in Table 1.
[0170] The nanoparticles were heat treated at in an oven roughly as
shown in FIG. 6. The particles were fed in batches of between about
100 grams to about 150 grams into the glass jar. Oxygen is fed
through a 1/8" stainless steel tube at an oxygen flow rate of 155
cc/min. A mixing speed of 5 rpm was used to constantly mix the
powders during the heat treatment. The powders were heated for 30
minutes at 100.degree. C., then for 30 minutes at 200.degree. C.
and finally at 230.degree. C. for 16 hours. A heating rate of
4.degree. C./minute was used to heat the samples to the target
temperatures. The resulting nanoparticles were single phase
crystalline V.sub.2O.sub.5 nanoparticles. The x-ray diffractogram
of this material is shown in FIG. 10. From the x-ray diffractogram,
it could be determined that the resulting particles were
orthorhombic V.sub.2O.sub.5.
[0171] TEM photographs were obtained of representative
nanoparticles following heat treatment. The TEM photograph is shown
in FIG. 11. An approximate size distribution was determined by
manually measuring diameters of the particles shown in FIG. 11. The
particle size distribution is shown in FIG. 12. An average particle
size of about 10-11 nm was obtained. Only those particles showing
clear particle boundaries were measured and recorded to avoid
regions distorted in the micrograph. This should not bias the
measurements obtained since the single view of the micrograph may
not show a clear view of all particles because of the orientation
of the crystals.
Example 3
Heat Processing to Form Silver Vanadium Oxide From V.sub.2O.sub.5
Nanoparticles
[0172] This example demonstrates the production of nanoscale silver
vanadium oxide using a vanadium oxide nanoparticle starting
material. The silver vanadium oxide is produced by heat
processing.
[0173] About 9.5 g of silver nitrate (AgNO.sub.3) (EM Industries,
Hawthorne, N.Y.) was dissolved into about 15 ml of deionized water.
Then, about 10 g of V.sub.2O.sub.5 nanoparticles produced as
described in Examples 2 were added to the silver nitrate solution
to form a mixture. The resulting mixture was stirred on a magnetic
stirrer for about 30 minutes. After the stirring was completed the
solution was heated to about 160.degree. C. in an oven to drive off
the water The dried powder mixture was ground with a mortar and
pestle.
[0174] Six samples from the resulting ground powder weighing
between about 100 and about 300 mg of nanoparticles were placed
separately into an open 1 cc boat. The boat was placed within the
quartz tube projecting through an oven to perform the heat
processing. The oven was essentially as described above with
respect to FIG. 7. Oxygen gas or argon gas was flowed through a 1.0
in diameter quartz tube at a flow rate of about 20 sccm. The
samples were heated in the oven under the following conditions:
2 1) 250.degree. C., 60 hrs in argon 2) 250.degree. C., 60 hrs in
oxygen 3) 325.degree. C., 4 hrs in argon 4) 325.degree. C., 4 hrs
in oxygen 5) 400.degree. C., 4 hrs in argon 6) 400.degree. C., 4
hrs in oxygen.
[0175] The samples were heated at approximately the rate of
2.degree. C./min. and cooled at the rate of approximately 1.degree.
C./min. The times given above did not include the heating and
cooling time.
[0176] The structure of the particles following heating was
examined by x-ray diffraction. The x-ray diffractograms for the
samples heated in oxygen and in argon are shown in FIGS. 13 and 14,
respectively. All of the heated samples produces diffractograms
with peaks indicating the presence of Ag.sub.2V.sub.4O.sub.11. The
samples heated at 400.degree. C. appear to lack significant amounts
of V.sub.2O.sub.5. Heating the samples for somewhat longer times at
the lower temperatures should eliminate any remaining portions of
the V.sub.2O.sub.5 starting material.
[0177] A transmission electron micrograph of the silver vanadium
oxide particles is shown in FIG. 15. For comparison, a transmission
electron micrograph of the V.sub.2O.sub.5 nanoparticle sample used
to form the silver vanadium oxide nanoparticles is shown in FIG.
16, at the same scale as FIG. 15. The V.sub.2O.sub.5 nanoparticles
in FIG. 16 were produced under conditions similar to the conditions
described in Examples 1 and 2. The silver vanadium oxide particles
in FIG. 15 surprisingly have a slightly smaller average diameter
than the vanadium oxide nanoparticle starting material in FIG.
16.
Example 4
Heat Processing to Form Silver Vanadium Oxide From VO.sub.2
Nanoparticles
[0178] This example demonstrates the production of nanoscale silver
vanadium oxide using a VO.sub.2 vanadium oxide nanoparticle
starting material. The silver vanadium oxide is produced by heat
processing.
[0179] VO.sub.2 nanoparticles were produced under similar
conditions as described above in Example 1. Ten grams of
nanocrystalline VO.sub.2 powder were washed with 500 ml of
deionized water to remove any residual chlorine. The washing was
performed in a Corning.RTM. 500 ml filter system with a 0.2 .mu.m
Nylon.RTM. membrane and a side arm for vacuum filtration. The
washed nanocrystalline VO.sub.2 powder was dried under vacuum at a
pressure less than thirty inches of mercury (750 Torr) for a
minimum of 12 hours, at a temperature between 100.degree. C. and
120.degree. C. The washed and dried nanocrystalline VO.sub.2 was
shaken in a SPEX.TM. 8000 mixer/mill for 15 minutes to break up
agglomerates.
[0180] Crystalline silver nitrate powder (99+purity) from EM
Industries (Hawthorne, N.Y.) were added quantitatively to the
deagglomerized nanocrystalline VO.sub.2 powder in a ratio of one
mole AgNO.sub.3 for 2 moles of VO.sub.2. This powder mixture was
ground in a Fritsch Mortar Grinder Model P-2 (Gilson Company, Inc.,
Worthington, Ohio) for twenty minutes. Following grinding, the
mixture was heated in a tube furnace, essentially as shown in FIG.
7, in a flowing oxygen atmosphere at a flow rate of 190 milliliters
of oxygen per minute.
[0181] The heat treatment consisted of heating from room
temperature to 180.degree. C. over an hour period, followed by an
equilibration time of at least one hour. Then, the temperature was
increased gradually to a temperature of about 400.degree. C. The
temperature was held at the final temperature for about 20 hours.
After heating at the final temperature for the desired period of
time, the product was cooled to room temperature over a 5 to 15
hour period.
[0182] The crystal structure of the resulting powders were examined
by x-ray diffraction. The x-ray diffractogram for the resulting
material is shown in FIG. 17. The diffractogram has sharp peaks
corresponding to silver vanadium oxide
(Ag.sub.2V.sub.4O.sub.11).
[0183] The resulting silver vanadium oxide nanoparticles were
further characterized by differential scanning calorimetry (DSC).
The DSC apparatus was a model Universal V2.3C DSC apparatus from TA
Instruments, Inc., New Castle, Del. The measured heat flow as a
function of temperature is plotted in FIG. 18. The curve shows only
two isotherms, corresponding to a peritectic transformation at
about 558.degree. and a eutectic point at about 545.degree.. These
transitions in silver vanadium oxide are described further in P.
Fleury, Rev. Chim. Miner., 6(5) 819 (1969).
[0184] No lower temperature endotherms were observed. In
particular, an endotherm at approximately 463.degree.,
corresponding to the melting of AgVO.sub.3, was not observed. Thus,
the DSC data suggests that the nanoscale silver vanadium oxide
material was compositionally pure with respect to other materials
having phase transitions up to the 600.degree. C. limit of the DSC
test.
[0185] This dry powder mixing approach was also used successfully
to produce silver vanadium oxide nanoparticles from a mixture of
nanocrystalline V.sub.2O.sub.5 and crystalline silver nitrate
powders, except that the washing step generally is unnecessary
since nanocrystalline V.sub.2O.sub.5 nanoparticles produced in a
heat treatment process do not contain residual chlorine.
Furthermore, the molar ratios are adjusted accordingly.
Example 5
Direct Laser Pyrolysis Synthesis of Nanoscale Silver--Vanadium
Oxide Materials
[0186] The synthesis of nanoscale silver--vanadium oxide materials
described in this example was performed by laser pyrolysis. The
particles were produced using essentially the laser pyrolysis
apparatus of FIG. 1, described above, using the reactant delivery
apparatus of FIG. 3A.
[0187] The solution for delivery as an aerosol in the reaction
chamber was produced with a vanadium precursor solution. To produce
the vanadium precursor solution, first a 20.0 g sample of vanadium
(III) oxide (V.sub.2O.sub.3) from Aldrich Chemical (Milwaukee,
Wis.) was suspended in 240 ml of deionized water. A 60 ml quantity
of 70% by weight aqueous nitric acid (HNO.sub.3) solution was added
dropwise to the vanadium (III) oxide suspension with vigorous
stirring. Caution was taken because the reaction with nitric acid
is exothermic and liberates a brown gas suspected to be NO.sub.2.
The resulting vanadium precursor solution was a dark blue
solution.
[0188] To produce the precursor solution for aerosol delivery, a
solution of silver nitrate (AgNO.sub.3) was prepared by dissolving
22.7 g of silver nitrate from Aldrich Chemical (Milwaukee, Wis.) in
a 200 ml volume of deionized water. To prepare a solution of metal
mixtures for aerosol delivery, the silver nitrate solution was
added to the vanadium precursor solution with constant stirring.
The resulting dark blue solution had a molar ratio of vanadium to
silver of about 2:1. Experiments using higher relative amounts of
silver yielded comparable results.
[0189] The aqueous solution with the vanadium and silver precursors
was carried into the reaction chamber as an aerosol. C.sub.2H.sub.4
gas was used as a laser absorbing gas, and Argon was used as an
inert gas. O.sub.2, Ar and C.sub.2H.sub.4 were delivered into the
gas supply tube of the reactant supply system. The reactant mixture
containing vanadium oxide, silver nitrate, Ar, O.sub.2 and
C.sub.2H.sub.4 was introduced into the reactant nozzle for
injection into the reaction chamber. The reactant nozzle had an
opening with dimensions of 5/8 in..times.1/4 in. Additional
parameters of the laser pyrolysis synthesis relating to the
particles of Example 1 are specified in Table 2.
3 TABLE 2 1 Crystal Structure Mixed Phase Pressure (Torr) 450
Argon-Window (SLM) 2.00 Argon-Shielding (SLM) 9.81 Ethylene (SLM)
0.73 Argon (SLM) 4.00 Oxygen (SLM) 0.96 Laser Power (input) 490-510
(Watts) Laser Power (output) 450 (Watts) Vanadium/Silver Mole 2:1
Ratio Precursor Temperature .degree. C. Room Temperature slm =
standard liters per minute Argon-Win. = argon flow through inlets
216, 218 Argon-Sld. = argon flow through annular channel 142. Argon
= Argon directly mixed with the aerosol
[0190] To evaluate the atomic arrangement, the samples were
examined by x-ray diffraction using the Cu(K.alpha.) radiation line
on a Siemens D500 x-ray diffractometer. X-ray diffractograms for a
sample produced under the conditions specified in Table 2 are shown
in FIG. 19. The diffractogram has peaks that can be identified as
VO.sub.2, V.sub.2O.sub.3, and elemental silver. Additional peaks in
the diffractograms of have not been correlated with known materials
and are discussed further in Example 7.
[0191] Powders of a sample produced under the conditions of Table 2
were further analyzed using transmission electron microscopy. The
TEM micrograph is shown in FIG. 20. The TEM micrograph has a
particles falling within different size distributions. This is
characteristic of mixed phase materials made by laser pyrolysis,
where each material generally has a very narrow particle size
distribution.
[0192] Furthermore, as described in the following Example, heat
treatment of these nanoscale silver--vanadium oxide materials in an
oxygen environment can result in crystalline
Ag.sub.2V.sub.4O.sub.11 in high yields.
Example 6
Heat Treatment of Laser Pyrolysis Produced Nanoscale
Silver--Vanadium Oxide Materials
[0193] This example demonstrates the production of nanoscale
crystalline silver vanadium oxide Ag.sub.2V.sub.4O.sub.11 starting
with nanoscale silver--vanadium oxide materials produced by laser
pyrolysis, as described in Example 5.
[0194] A sample silver--vanadium oxide powder corresponding to a
sample from Example 5 weighing between about 300 and about 700 mg
of nanoparticles were placed into an open 1 cc boat. The boat was
placed within the quartz tube projecting through an oven to perform
the heat processing. The oven was essentially as described above
with respect to FIG. 7. Oxygen gas was flowed through a 1.0 in
diameter quartz tube at a flow rate of about 30 sccm.
[0195] The heat treatment consisted of heating from room
temperature to 180.degree. C. over an hour period, followed by an
equilibration time of at least one hour. Then, the temperature was
increased approximately at a rate of 3.degree. C. per minute to a
temperature of about 360.degree. C. The temperature was held at the
final temperature for 16.5 hours. After heating at the final
temperature for the desired period of time, the product was cooled
to room temperature at a rate of about 1 degree per minute. The
heating time given above did not include the heating and cooling
time.
[0196] The structure of the particles following heating was
examined by x-ray diffraction. The x-ray diffractograms for the
sample following heating is shown in FIG. 21. The heat treated
powders were also examined by transmission electron microscopy. A
TEM micrograph of the samples is shown in FIG. 22.
Example 7
Direct Laser Pyrolysis Synthesis of Silver Vanadium Oxide
Nanoparticles
[0197] The syntheses of silver vanadium oxide nanoparticles
described in this example was performed by laser pyrolysis. The
particles were produced using essentially the laser pyrolysis
apparatus of FIG. 1, described above, using the reactant delivery
apparatus of FIGS. 3A or 3B.
[0198] Two solutions were prepared for delivery into the reaction
chamber as an aerosol. Both solutions were produced with comparable
vanadium precursor solutions. To produce the first vanadium
precursor solution, a 10.0 g sample of vanadium (III) oxide
(V.sub.2O.sub.3) from Aldrich Chemical (Milwaukee, Wis.) was
suspended in 120 ml of deionized water. A 30 ml quantity of 70% by
weight aqueous nitric acid (HNO.sub.3) solution was added dropwise
to the vanadium (III) oxide suspension with vigorous stirring.
Caution was taken because the reaction with nitric acid is
exothermic and liberates a brown gas suspected to be N0.sub.2. The
resulting vanadium precursor solution (about 150 ml) was a dark
blue solution. The second vanadium precursor solution involved the
scale-up of the first precursor solution by a factor of three in
all ingredients.
[0199] To produce a first silver solution, a solution of silver
carbonate (Ag.sub.2CO.sub.3) from Aldrich Chemical (Milwaukee,
Wis.) was prepared by suspending 9.2 g of silver carbonate in a 100
ml volume of deionized water. A 10 ml quantity of 70% by weight
aqueous nitric acid (HNO.sub.3) was added dropwise with vigorous
stirring. A clear colorless solution resulted upon completion of
the addition of nitric acid. To produce a first metal mixture
solution for aerosol delivery, the silver solution was added to the
first vanadium precursor solution with constant stirring. The
resulting dark blue first metal mixiure solution had a molar ratio
of vanadium to silver of about 2:1.
[0200] To produce a second silver solution, 34.0 g of silver
nitrate (AgNo.sub.3) from Aldrich Chemical (Milwaukee, Wis.) was
dissolved in a 300 ml volume of deionized water. To prepare a
second solution of metal mixtures for aerosol delivery, the silver
nitrate solution was added to the second vanadium precursor
solution with constant stirring. The resulting dark blue second
metal mixture solution also had a molar ratio of vanadium to silver
of about 2:1.
[0201] The selected aqueous solution with the vanadium and silver
precursors was carried into the reaction chamber as an aerosol.
C.sub.2H.sub.4 gas was used as a laser absorbing gas, and Argon was
used as an inert gas. O.sub.2, Ar and C.sub.2H.sub.4 were delivered
into the gas supply tube of the reactant supply system. The
reactant mixture containing vanadium oxide, silver nitrate, Ar,
O.sub.2 and C.sub.2H.sub.4 was introduced into the reactant nozzle
for injection into the reaction chamber. The reactant nozzle had an
opening with dimensions of 5/8 in..times.1/4 in. Additional
parameters of the laser pyrolysis synthesis relating to the
particle synthesis are specified in Table 3. Sample 1 was prepared
using the reactant delivery system essentially as shown in FIG. 3A
while sample 2 was prepared using the reactant delivery system
essentially as shown in FIG. 3B.
4 TABLE 3 1 2 Crystal Structure Mixed Phase Mixed Phase Pressure
(Torr) 600 600 Argon-Window (SLM) 2.00 2.00 Argon-Shielding (SLM)
9.82 9.86 Ethylene (SLM) 0.74 081 Argon (SLM) 4.00 4.80 Oxygen
(SLM) 0.96 1.30 Laser Power (input) 490-531 390 (Watts) Laser Power
(output) 445 320 (Watts) Precursor Solution 1 2 Precursor
Temperature Room Room .degree. C. Temperature Temperature slm =
standard liters per minute Argon-Win. = argon flow through inlets
216, 218 Argon-Sid. = argon flow through annular channel 142. Argon
= Argon directly mixed with the aerosol
[0202] To evaluate the atomic arrangement, the samples were
examined by x-ray diffraction using the Cu(K.alpha.) radiation line
on a Siemens D500 x-ray diffractometer. X-ray diffractograms for
samples 1 (lower curve) and 2 (upper curve) produced under the
conditions specified in Table 3 are shown in FIG. 23. The samples
had peaks corresponding to VO.sub.2, elemental silver and peaks
that did not correspond to known materials. A significant
crystalline phase for these samples had peaks at 2 .theta. equal to
about 30-31.degree., 32, 33 and 35. This phase is thought to be a
previously unidentified silver vanadium oxide phase. This phase is
observed in samples prepared by mixing vanadium oxide nanoparticles
and silver nitrate under conditions where the samples are heated
for an insufficient time period to produce Ag.sub.2V.sub.4O.sub.11.
Specific capacity measurements of sample 1 in a coin cell,
presented below, are consistent with this interpretation. These
peaks in smaller amounts are also observed in the samples produced
under the conditions described in Example 5.
[0203] Powders of samples produced under the conditions specified
in Table 3 were further analyzed using transmission electron
microscopy. The TEM micrographs are shown in FIGS. 24A (first
column of Table 3) and 24B (second column of Table 3). The TEM
micrograph has a particles falling within different size
distributions. This is characteristic of mixed phase materials made
by laser pyrolysis, where each material generally has a very narrow
particle size distribution. The portion of silver vanadium oxide in
the mixed phase material should be increased by an increase in
oxygen flow, a decrease in laser power and an increase in
pressure.
Example 8
Direct Laser Pyrolysis Synthesis of Silver Vanadium Oxide
Nanoparticles
[0204] The synthesis of silver vanadium oxide nanoparticles
described in this example was performed by laser pyrolysis. The
particles were produced using essentially the laser pyrolysis
apparatus of FIG. 1, described above, using the reactant delivery
apparatus of FIG. 3B.
[0205] A solution was prepared for delivery into the reaction
chamber as an aerosol. To produce the first vanadium precursor
solution, a 20.0 g sample of vanadium (III) oxide (V.sub.2O.sub.3)
from Aldrich Chemical (Milwaukee, Wis.) was suspended in 240 ml of
deionized water. A 60 ml quantity of 70% by weight aqueous nitric
acid (HNO.sub.3) solution was added dropwise to the vanadium (III)
oxide suspension with vigorous stirring. Caution was taken because
the reaction with nitric acid is exothermic and liberates a brown
gas suspected to be NO.sub.2. The resulting vanadium precursor
solution (about 300 ml) was a dark blue solution.
[0206] Five different silver solutions were prepared to produce a
solution for aerosol delivery with varying ratios of silver to
vanadium. To produce the silver solutions, a quantity of silver
nitrate (AgNO.sub.3) from Aldrich Chemical (Milwaukee, Wis.) was
dissolved in a 200 ml volume of deionized water. The five silver
solutions had the following grams of silver nitrate: 1) 15.9 g, 2)
18.1 g, 3) 20.4 g, 4) 22.7 g, 5) 23.8 g. To prepare solutions of
metal mixtures for aerosol delivery, the silver nitrate solution
was added to a vanadium precursor solution with constant stirring.
The resulting dark blue second metal mixture solution. The five
solutions had the following molar ratio of silver to vanadium: 1)
0.7:2, 2) 0.8:2, 3) 0.9:2, 4) 1.0:2, 5) 1.05:2.
[0207] The selected aqueous solution with the vanadium and silver
precursors was carried into the reaction chamber as an aerosol.
C.sub.2H.sub.4 gas was used as a laser absorbing gas, and Argon was
used as an inert gas. O.sub.2, Ar and C.sub.2H.sub.4 were delivered
into the gas supply tube of the reactant supply system. The
reactant mixture containing vanadium oxide, silver nitrate, Ar,
O.sub.2 and C.sub.2H.sub.4 was introduced into the reactant nozzle
for injection into the reaction chamber. The reactant nozzle had an
opening with dimensions of 5/8 in..times.1/4 in. Additional
parameters of the laser pyrolysis synthesis relating to the
particle synthesis are specified in Table 4.
5 TABLE 4 Crystal Structure Mixed Phase Pressure (Torr) 600
Argon-Window (SLM) 2.00 Argon-Shielding (SLM) 9.86 Ethylene (SLM)
0.81 Argon (SLM) 0.80 Oxygen (SLM) 1.30 Laser Power (input) 390
(Watts) Laser Power (output) 320 (Watts) Precursor Temperature Room
.degree. C. Temperature slm = standard liters per minute Argon-Win.
= argon flow through inlets 216, 218 Argon-Sid. = argon flow
through annular channel 142. Argon = Argon directly mixed with the
aerosol
[0208] To evaluate the atomic arrangement, the samples were
examined by x-ray diffraction using the Cu(K.alpha.) radiation line
on a Siemens D500 x-ray diffractometer. X-ray diffractograms for
samples 1-5 produced under the conditions specified in Table 4 are
shown in FIG. 25. The samples had peaks corresponding to VO.sub.2,
elemental silver, possibly V.sub.2O.sub.3 and peaks that did not
correspond to known materials. A significant crystalline phase for
these samples had peaks at 2 .theta. equal to about 30-31.degree.,
32, 33 and 35. As noted above, this phase is thought to be a
previously unidentified silver vanadium oxide phase. Under these
conditions, as the silver to vanadium ratio increased, the peaks
corresponding to vanadium oxide decreased. Evidently, additional
amorphous components containing vanadium, oxygen and possibly
silver were produced when the relative amount of silver was
increased.
Example 9
Laser Pyrolysis Production of Elemental Silver Nanoparticles
[0209] The synthesis of elemental silver nanoparticles described in
this example was performed by laser pyrolysis. The particles were
produced using essentially the laser pyrolysis apparatus of FIG. 1,
described above, using the reactant delivery apparatus of FIG.
3A.
[0210] A 1 molar silver nitrate solution was prepared for delivery
into the reaction chamber as an aerosol by dissolving 50.96 g of
silver nitrate (Aldrich Chemical, Milwaukee, Wis.) into 300 ml
deionized water to produce a clear solution. C.sub.2H.sub.4 gas was
used as a laser absorbing gas, and Argon was used as an inert gas.
O.sub.2, Ar and C.sub.2H.sub.4 were delivered into the gas supply
tube of the reactant supply system. The reactant mixture containing
silver nitrate, Ar, O.sub.2 and C.sub.2H.sub.4 was introduced into
the reactant nozzle for injection into the reaction chamber. The
reactant nozzle had an opening with dimensions of 5/8 in..times.1/4
in. Additional parameters of the laser pyrolysis synthesis relating
to the particle synthesis are specified in Table 5.
6 TABLE 5 1 2 face centered face centered Crystal Structure cubic
cubic Pressure (Torr) 450 450 Argon-Window (SLM) 2.00 2.00
Argon-Shielding (SLM) 9.82 9.82 Ethylene (SLM) 1.342 0.734 Argon
(SLM) 5.64 3.99 Oxygen (SLM) 1.41 0.96 Laser Power (input) 970 490
(Watts) Laser Power (output) 800 450 (Watts) Production Rate 1.44
1.02 (gram/hour) Precursor Temperature Room Room .degree. C.
Temperature Temperature slm = standard liters per minute Argon-Win.
= argon flow through inlets 216, 218 Argon-Sld. = argon flow
through annular channel 142. Argon = Argon directly mixed with the
aerosol
[0211] To evaluate the atomic arrangement, the samples were
examined by x-ray diffraction using the Cu(K.alpha.) radiation line
on a Siemens D500 x-ray diffractometer. X-ray diffractograms for
sample 1 and sample 2 produced under the conditions specified in
Table 5 are shown in FIGS. 26 and 27, respectively. The samples had
strong peaks corresponding to elemental silver.
[0212] Powders produced under the conditions of column 1 of Table 5
were further analyzed using transmission electron microscopy. The
TEM micrograph is shown in FIG. 28. The particle size distribution
in the TEM micrograph is broad relative to particle size
distributions involving laser pyrolysis synthesis. The particle
size distribution can be narrowed significantly by either using gas
phase precursors or a more uniform aerosol delivery.
[0213] Representative particles were also analyzed by elemental
analysis. A typical elemental analysis of these materials yielded
in weight percent about 93.09% silver, 2.40% carbon, 0.05%
hydrogen, and 0.35% nitrogen. Oxygen was not directly measured and
may have accounted for some of the remaining weight. The elemental
analysis was performed by Desert Analytics, Tucson, Ariz.
[0214] The carbon component in the nanoparticles likely is in the
form of a coating. Such carbon coatings can be formed from the
carbon introduced by ethylene within the reactant stream.
Generally, the carbon can be removed by heating under an oxidizing
atmosphere under mild conditions. The removal of such carbon
coatings is described further in copending and commonly assigned,
U.S. patent application Ser. No. 09/123,255, entitled "Metal
(Silicon) Oxide/Carbon Composite Particles," incorporated herein by
reference.
[0215] Since other group IB elements, copper and gold, have similar
chemical properties as silver, substitution of copper or gold
precursors for the silver precursors under similar conditions
should result in the production of elemental copper or gold
nanoparticles.
Example 10
Lithium Batteries Formed With Silver Vanadium Oxide
Nanoparticles
[0216] This example demonstrates the suitability of silver vanadium
oxide particles for the production of lithium based batteries and
the attainability of an increased capacity.
[0217] To produce a test cell incorporating silver vanadium oxide
produced according to one of the Examples above, a desired quantity
of silver vanadium oxide nanoparticles was weighed and combined
with predetermined amounts of graphite powder (Chuetsu Graphite
Works, CO., Osaka, Japan) and acetylene black powder (Catalog
number 55, Chevron Corp.) as conductive diluents, and a 60% by
weight dispersion of Teflon.RTM. (Catalog No. 44,509-6, Aldrich
Chemical Co., Milwaukee, Wis.) in water as a binder. The mixture
included 70% by weight silver vanadium oxide nanoparticles, 10% by
weight graphite, 10% by weight acetylene black, and 10% by weight
Teflon.RTM.. The resulting combination was mixed well, kneaded, and
rolled into a one-millimeter thick sheet. An approximately
two-square centimeter area disk was cut from the sheet. The disk
was then dried and pressed in a 1.6 cm diameter die set at 12,000
pounds for 45-60 seconds to form a dense pellet The pressed pellet
was vacuum dried and weighed.
[0218] The pressed and dried disk was used as the active cathode in
a 2025 coin cell. To form the coin cell, a 1.6 square centimeter
disk of nickel expanded metal was punched and resistance welded as
a current collector to the inside of the stainless steel cover of
the 2025 coin cell hardware (catalog No. 10769, Alfa Aesar, Inc.,
Ward Hill, Mass.). Battery grade lithium foil (0.75 mm thick) from
Hohsen Corp. (Osaka Japan) was punched into a two-square centimeter
disk and cold welded to the nickel expanded metal. A microporous
polypropylene separator disk (Celgard.RTM. 2400, Hoechst-Celanese,
Charlotte, N.C.) of appropriate dimensions was placed over the
lithium disk.
[0219] A predetermined amount of electrolyte was added to this
separator/lithium assembly. The electrolyte solution was composed
of 1M LiPF.sub.6 salt. The solvent for the electrolyte solution was
a 1:1 volume ratio of ethylene carbonate to dimethyl carbonate. A
second 1.6 square centimeter disk of stainless steel expanded metal
was punched and resistance welded to the inside of the stainless
steel can of the 2025 coin cell hardware. The active cathode pellet
was placed on the nickel expanded metal and mated with the above
separator/lithium assembly. The stainless steel can and stainless
steal cover are separated from each other by a polypropylene
grommet. The mated assembly was crimped together and employed as a
test coin cell.
[0220] The measurements were controlled by a Maccor Battery Test
System, Series 4000, from Maccor, Inc. (Tulsa, Okla.). The
discharge profile was recorded, and the discharge capacity of the
active material was obtained.
[0221] To form a first coin cell, a cathode pellet was formed from
0.143 g of nanoscale silver vanadium oxide formed by heat
processing of nanoscale VO.sub.2 and silver nitrate, as described
above in Example 4. The open circuit voltage immediately after
crimping was 3.53 volts. The cell was placed in a controlled
atmosphere chamber at 37.+-.1 degrees C. and allowed to equilibrate
for 4 hours. Then, the cell was subjected to a constant current
discharge of 0.1 milliamperes per square centimeters of active
interfacial electrode surface area. When the voltage reached 1.0
volt, the discharge current was allowed to decay as the cell
voltage was held at 1.0 volt for five hours. The 1.0 volt discharge
allows for a capacity measurement independent of polarization
effects that result from discharge at finite values of current.
This yields a capacity measurement that more closely approximates
the maximum value that would be obtained with by discharging the
battery at infinitely slow discharge.
[0222] The voltage as a function of time is plotted in FIG. 29. The
first four hours in the plot were taken during temperature
equilibration and do not involve any battery discharge. A plot of
voltage as a function of cumulative capacity is plotted in FIG. 30.
The cumulative discharge capacity was measured as 51.0
milliampere-hours, or a specific capacity of about 357 milliampere
hours per gram of active silver vanadium oxide nanoparticles. This
is greater than the theoretical specific capacity.
[0223] A second cell was constructed as described above with silver
vanadium oxide as directly synthesized, as described above in
Example 5. The cathode contained 0.148 g of nanoscale silver
vanadium oxide particles. The open circuit voltage immediately
after crimping was 3.3 volts. The cell was placed in a controlled
atmosphere chamber at 37.+-.1 degrees, allowed to equilibrate for 4
hours. The cell was subjected to a constant current discharge of
0.309 milliamperes per square centimeter of active interfacial
electrode surface area. When the voltage reached 1.0 volt, the
discharge current was allowed to decompose as the cell voltage was
held at 1.0 volt for five hours.
[0224] The voltage-time results are illustrated in FIG. 31. The
first four hours in the plot were taken during temperature
equilibration and do not involve any battery discharge. A plot of
voltage versus cumulative capacity is given in FIG. 32. As
illustrated, the cumulative discharge capacity was measured at 15.4
milliampere-hours, or specific capacity of approximately 104.3
milliampere-hours per gram of active silver vanadium oxide
nanoparticles. The discharge capacity was evaluated by the integral
over the discharge time of the voltage multiplied by the current
divided. The specific capacity was evaluated as the discharge
capacity divided by the mass of the active material.
[0225] A third cell was constructed as described above with silver
vanadium oxide synthesized by laser pyrolysis with subsequent
annealing in an oven, as described above in Example 6. The active
cathode pellet contained 0.157 g of silver vanadium oxide
nanoparticles. The open cell voltage immediately after crimping was
3.5 volts. The cell was placed in a controlled atmosphere chamber
at 37.+-.1.degree. C. and allowed to equilibrate for 4 hours. Then,
the cell was subjected to a constant current discharge of 0.100
milliamperes per square centimeter of active interfacial electrode
surface area. When the voltage reached 1.0 volt, the discharge
current was allowed to decompose as the cell voltage was held at
1.0 volt for five hours.
[0226] The voltage-time results are illustrated in FIG. 33. The
first four hours in the plot were taken during temperature
equilibration and do not involve any battery discharge. A plot of
voltage versus cumulative capacity is given in FIG. 34. As
illustrated, the cumulative discharge capacity was measured at
63.53 milliampere-hours, or a specific capacity of approximately
404 milliampere-hours per gram of active silver vanadium oxide
nanoparticles.
[0227] A fourth cell was constructed as described above with silver
vanadium oxide synthesized by laser pyrolysis, as described above
in Example 7 under conditions specified in the first column of
Table 3. The active cathode pellet contained 0.154 g of silver
vanadium oxide nanoparticles. The open cell voltage immediately
after crimping was 3.4 volts. The cell was placed in a controlled
atmosphere chamber at 37.+-.1.degree. C. and allowed to equilibrate
for 4 hours. Then, the cell was subjected to a constant current
discharge of 0.309 milliamperes per square centimeter of active
interfacial electrode surface area. When the voltage reached 1.0
volt, the discharge current was allowed to decompose as the cell
voltage was held at 1.0 volt for five hours.
[0228] The voltage-time results are illustrated in FIG. 35. The
first four hours in the plot were taken during temperature
equilibration and do not involve any battery discharge. A plot of
voltage versus cumulative capacity is given in FIG. 36. The voltage
plots shown in FIGS. 35 and 36 have a shape characterized by silver
vanadium oxide signatures. As illustrated, the cumulative discharge
capacity was measured at 35.54 milliampere-hours, or a specific
capacity of approximately 230 milliampere-hours per gram of active
silver vanadium oxide nanoparticles. The low specific capacity
suggests that the silver vanadium oxide particles were part of a
mixed phase material.
[0229] A theoretical capacity of 315 milliampere-hours per gram (7
equivalents of lithium) for Ag.sub.2V.sub.4O.sub.11 has been
reported, see Takeuchi et al., "The Reduction of Silver Vanadium
Oxide in Lithium/Silver Vanadium Oxide Cells, J. Electrochem. Soc.
135:2691 (November 1988) and Leising et al., Journal of Power
Sources 68:730-734 (1997), both of which are incorporated herein by
reference Thus, value of specific capacity obtained in the Examples
described herein significantly exceed the theoretical values.
[0230] The embodiments described above are intended to be
illustrative and not limiting. Additional embodiments are within
the claims below. Although the present invention has been described
with reference to preferred embodiments, workers skilled in the art
will recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *